ETAS LABCAR-MODEL V4.

User Guide
Copyright
The data in this document may not be altered or amended without special noti-
fication from ETAS GmbH. ETAS GmbH undertakes no further obligation in
relation to this document. The software described in it can only be used if the
customer is in possession of a general license agreement or single license.
Using and copying is only allowed in concurrence with the specifications stipu-
lated in the contract.
Under no circumstances may any part of this document be copied, reproduced,
transmitted, stored in a retrieval system or translated into another language
without the express written permission of ETAS GmbH.
© Copyright 2020 ETAS GmbH, Stuttgart
The names and designations used in this document are trademarks or brands
belonging to the respective owners. MATLAB and Simulink are registered trade-
marks of The MathWorks, Inc..Windows is a registered trademark of
Microsoft Corporation.
LABCAR-MODEL V4.3 - User Guide R01 EN - 12.2020
ETAS Contents

Contents
1 About this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Classification of Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Presentation of Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Typographical Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Presentation of Supporting Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6 Privacy Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6.1 Data Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.6.2 Data and Data Categories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.6.3 Technical and Organizational Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 LABCAR-MODEL Family. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Overview of Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 General Model Parametrization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.1 Obtaining the Data for Parametrization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.2 Model Parametrization Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Technical Aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3.1 LABCAR Port Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3.2 Simulink Model - Code Generation Process . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3.3 MEX File Version Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3.4 Mapping External Files for HiL Execution . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4 LABCAR-MODEL Based FMUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4.1 FMU Exporter Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4.2 FMIKit-Simulink Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 User Privileges Required for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Contents of the DVD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3 Program Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4 Contents of the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4 LABCAR-MODEL-VVTB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 Project and Experiment Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1.1 Project Creation in COSYM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1.2 Project Creation in LABCAR-OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.1.3 Experiment Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.2 Getting Started with the Tutorial Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.2.2 Cycle Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.3 Signal Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.3.1 Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.3.2 SoftECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.3.3 Vehicle/Drivetrain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.3.4 Vehicle/CombustionEngine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.3.5 Driver/BodyComponents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.4 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

LABCAR-MODEL V4.3 - User Guide 3

ETAS Contents

4.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.4.2 Driver Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.4.3 Controlling the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

5 LABCAR-MODEL-ICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.1 Project and Experiment Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.1.1 Project Creation in COSYM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.1.2 Project Creation in LABCAR-OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.1.3 Experiment Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.2 Getting Started with the Tutorial Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.2.2 Model Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.2.3 Manipulation of Air Mass Flow into Cylinder Through Throttle Plate. . . 81
5.3 Signal Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.3.1 Combustion Engine/Top Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.3.2 Combustion Engine/Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.3.3 Combustion Engine/Lambda Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.3.4 Combustion Engine/Throttle Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.3.5 Combustion Engine/Engine Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

6 LABCAR-MODEL-PMSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.2 Project and Experiment Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.2.1 Flashing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.2.2 Project Creation in LABCAR-OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.2.3 Experiment Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.3 Getting Started with Tutorial Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6.3.1 Active Short-Circuit Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6.4 Nonlinear Maps and Parameter Maps Downloader . . . . . . . . . . . . . . . . . . . . . . . . . 108
6.5 Signal Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.5.1 Drivetrain Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.5.2 Inverter Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.5.3 PMSM Motor Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.5.4 License Keys Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.5.5 Analog Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.5.6 Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.6 User Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.6.1 PMSM Runtime License . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.6.2 PMSM Simulation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.6.3 PMSM DAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.6.4 PMSM Failure Simulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.6.5 PMSM Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
6.6.6 PMSM Drivetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.7 Migration from PMSM Model for ES5340 V1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.7.1 FlexibleFPGA License . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.7.2 Flashing of FPGA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.7.3 RTIO Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.7.4 License Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
6.7.5 Parameters and Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

7 LABCAR-MODEL-FC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.1 Project and Experiment Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

LABCAR-MODEL V4.3 - User Guide 4

ETAS Contents

7.1.1 Project Creation in COSYM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

7.1.2 Project Creation in LABCAR-OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 143
7.1.3 Experiment Creation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.2 Getting Started with the Tutorial Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.2.2 Manual Control of Humidifier and Bypass . . . . . . . . . . . . . . . . . . . . . . . . 153
7.2.3 Adaptation of the Operation Strategy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7.3 Fuel-Cell Subsystems and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.3.1 Cathode Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.3.2 Hydrogen Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.3.3 Coolant Supply System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.3.4 Stack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.4 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7.4.2 GUI Section User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
7.4.3 GUI Sections for Observation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

8 Licensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
8.1 FPGA-Based Simulation Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
8.1.1 License Status Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
8.2 Simulink-Based Simulation Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
8.2.1 License Status Information (Windows) . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
8.2.2 License Status Information (RTPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

LABCAR-MODEL V4.3 - User Guide 5

ETAS About this Document

1 About this Document

1.1 Introduction
This document addresses qualified personnel working in the fields of automo-
tive ECU development and testing. Specialized knowledge in the areas of
embedded systems and simulation is required.
This document describes the handling and the licensing of the LABCAR-
MODEL simulation models and contains the following sections:
• “LABCAR-MODEL Family” on page 9
• “Installation” on page 25
• “LABCAR-MODEL-VVTB” on page 28
• “LABCAR-MODEL-ICE” on page 61
• “LABCAR-MODEL-PMSM” on page 88
• “LABCAR-MODEL-FC” on page 137
• “Licensing” on page 161
• “Glossary” on page 163
• “References” on page 165

1.2 Classification of Safety Messages

The safety messages used here warn of dangers that can lead to personal
injury or damage to property:

DANGER
indicates a hazardous situation with a high risk of death or serious injury if
not avoided.

WARNING
indicates a hazardous situation of medium risk, which could result in death or
serious injury if not avoided.

CAUTION
indicates a hazardous situation of low risk, which may result in minor or mod-
erate injury if not avoided.

NOTICE
indicates a situation, which may result in damage to property if not avoided.

LABCAR-MODEL V4.3 - User Guide 6

ETAS About this Document

1.3 Presentation of Instructions

The target to be achieved is defined in the heading. The necessary steps for his
are in a step-by-step guide:
Target definition
1. Step 1
2. Step 2
3. Step 3
> Result

1.4 Typographical Conventions

Software
OCI_CANTxMessage msg0 = Code snippets are presented in the Courier
font.
Meaning and usage of each command are
ex-plained by means of comments. The
comments are enclosed by the usual syntax
for comments.
Choose File  Open. Menu commands are shown in boldface.
Click OK. Buttons are shown in boldface.
Press <ENTER>. Keyboard commands are shown in angled
brackets in small caps.
The "Open File" dialog box is Names of program windows, dialog boxes,
displayed. fields, etc. are shown in quotation marks.
Select the file setup.exe. Text in drop-down lists on the screen, pro-
gram code, as well as path- and file names
are shown in the Courier font.
A distribution is always a one- General emphasis and new terms are set in
dimensional table of sample italics.
points.

1.5 Presentation of Supporting Information

NOTE
Contains additional supporting information.

1.6 Privacy Notice

Your privacy is important to ETAS. We have created the following privacy notice
that informs you, which data are processed in LABCAR-MODEL, which data cat-
egories LABCAR-MODEL uses, and which technical measure you have to take
to ensure the privacy of the users. Additionally, we provide further instructions
where this product stores and where you can delete personal or person-related
data.

LABCAR-MODEL V4.3 - User Guide 7

ETAS About this Document

1.6.1 Data Processing

Note that personal or person-related data respectively data categories are pro-
cessed when using this product. The purchaser of this product is responsible
for the legal conformity of processing the data in accordance with Article 4 No.
7 of the General Data Protection Regulation (GDPR). As the manufacturer,
ETAS GmbH is not liable for any mishandling of this data.

1.6.2 Data and Data Categories

When using the ETAS License Manager in combination with user-based
licenses, particularly the following personal or person-related data respectively
data categories can be recorded for the purposes of license management:
• Communication data: IP address
• User data: UserID, WindowsUserID

1.6.3 Technical and Organizational Measures

This product does not itself encrypt the personal or person-related data respec-
tively data categories that it records. Please ensure the data security of the
recorded data by suitable technical or organizational measures of your IT sys-
tem, e.g., by classical anti-theft and access protection on the hardware.
Personal or person-related data in log files can be deleted by tools in the oper-
ating system.

LABCAR-MODEL V4.3 - User Guide 8

ETAS LABCAR-MODEL Family

2 LABCAR-MODEL Family

2.1 Overview of Models

The ETAS LABCAR solutions provide ways for testing and validating (TV) a
wide range of automotive ECUs. The usage of numerical simulation models,
which mimic the physical behavior of the System under test (SUT), is a widely
known method. It offers many advantages over using real equipment as SUT,
like reproducibility of results, parallel execution, access to all physical and aux-
iliary quantities, and the possibility of reconfiguration when a different SUT is
needed. Frequently, such models do not resemble all the details of the SUT, but
cover only the relevant aspects needed for a closed-loop operation. Thus, the
simulation models are a vital part of the entire TV solution; without a model, no
closed-loop operation is possible.
The ETAS LABCAR-MODEL product family encompasses several domain-spe-
cific simulation models and the virtual vehicle test bench. The former models
mimic the functionality of a SUT for a single domain. Currently, the following
models are available:
• ETAS LABCAR-MODEL-FC is a realtime-capable simulation model of a
fuel-cell system including a PEM fuel-cell stack, a hydrogen supply, an
oxygen supply, and a coolant supply. The stack model includes a 1-D
membrane model for a detailed description of the membrane resistance,
water content, and the resulting water exchange between the electrodes.
ETAS LABCAR-MODEL-FC allows you to perform test and validation of
an automotive fuel-cell control unit (FCCU) in closed-loop.
• ETAS LABCAR-MODEL-ICE is a generic model of a Diesel, gasoline, and
CNG internal combustion engine (ICE) and its subsystems. It includes
detailed models of the combustion system, the fuel system, the intake
and exhaust system, and the aftertreatment system. This model allows
you to do test and validation of an engine management system (EMS).
• ETAS LABCAR-MODEL-PMSM is an FPGA-based model for a permanent
magnet synchronous electrical motor. It offers high performance and
low latency computations. This model allows you to do test and valida-
tion of an e-motor control unit (MCU).
• ETAS LABCAR-MODEL-VVTB is the virtual vehicle test-bench (VVTB). It
contains simplistic models for all the components that make up a virtual
vehicle. It serves as the integration platform with generic interfaces for
all other - typically more sophisticated - plant models. You can extend
LABCAR-MODEL-VVTB by your own domain-specific simulation models
or you can extend it by one of the domain-specific simulation models of
the ETAS LABCAR-MODEL family.

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ETAS LABCAR-MODEL Family

2.2 General Model Parametrization

2.2.1 Obtaining the Data for Parametrization

The most important point for every parametrization is the determination of the
correct data.
The first step in the model parametrization is collecting parametrization data.
For this purpose, each LABCAR-MODEL product comes with a detailed model
reference guide including a parameter list. You can query the availability of
each parameter.
There are several sources of the data. You can take model parameters directly
from an ECU. The prerequisite for this is a calibrated ECU software. It is essen-
tial that the ECU data used for the model parametrization is consistent with the
data used in the ECU.
The second possibility involves the parameters for the parametrization of the
open-loop model. This guarantees the correct generation and measurement of
signals. This is the foundation of a LABCAR operation.
The actual model parameters are addressed in the third step. This part con-
tains the most important parameters of the standard model variants.
The last step is for other tasks, which depend on the project in terms of the
parametrization. Further sources of information for the parametrization are
data sheets for special vehicle components, measurement protocols from the
engine test bench, or other accessible data.

NOTE
If you have an existing LABCAR-OPERATOR project, you may reduce the
amount of work needed for the parametrization by using your old parameters
as a starting point. The release notes of LABCAR-MODEL list all changes in
the meaning of the parameters between the different versions.

2.2.2 Model Parametrization Process

The model parametrization distinguishes between offline and online parametri-
zation. The two ways are described in the following sections.

2.2.2.1 General Parametrization Process

LABCAR-MODEL products provide several predefined configurations, e.g., dif-
ferent engine configurations, which include plausible default values for param-
etrization. In the context of the parametrization process, these default data
sets define the starting point for individual adaptations to suit the respective
project. This takes place in two main steps, the offline and the online parame-
trization. Once the parametrization is completed, the model can be productively
used to test a real or virtual ECU by modifying the parameters, using their inter-
faces. Furthermore, you can modify the model to execute error simulations.
While the model is in use for test and validation, new demands for adjusting
parameters arise or additional data for parametrization is supplied. In that
case, the parametrization has to be re-applied following the same parametriza-
tion strategy as initially. This procedure is depicted in Fig. 2-1.

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ETAS LABCAR-MODEL Family

Fig. 2-1 General Parametrization Workflow

2.2.2.2 Offline Parametrization

Before the offline parametrization you select the best fitting initial model con-
figuration for the particular project. With that, you define the fundamental vehi-
cle topology, e.g., the amount of engine turbochargers fitting its engine
topology.
The parametrization starts focusing on fundamental parameters. Here, you
can eliminate existing deviations between initial model and desired vehicle
model configuration, e.g., by setting the number of cylinders. In a second step,
you set parameters which contribute to the precision of the model. In that stage
of precise parametrization, you can set parameters which are responsible for
the "fine tuning" of the model. Execute this part of the offline parametrization
only if data is available for precise parametrization.

2.2.2.3 Online Parametrization

Once the offline parametrization is completed, you can continue with the online
parametrization. The unit under test, either a physical or a virtual ECU, is now
connected to the project. Ensure that the parameter file from the offline param-
etrization is available in LABCAR-EE and the simulation is running.
For a successful online parametrization do the following
1. Calibrate the ECU.
2. If used, configure and check the hardware boards. (Then sig-
nals are measured and sent correctly).

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ETAS LABCAR-MODEL Family

3. Correctly set the parameters in the open-loop model.

Like the offline parametrization, the online basic parametrization involves the
parameters being modified in the same order, i.e., according to the model func-
tionalities. See figure Fig. 2-2 on page 12. You only select insufficiently parame-
trized model functionalities iteratively and deactivate the model or the ECU
functionality, which is not in focus. If available, all the switch parameters are
checked. This could actually solve the problem of insufficient parametrization.
If not, steady-state operating points are set in the model at which the simula-
tion results are compared with target values, e.g., the engine test bench mea-
surements. You adapt the relevant parameters until the model precision is
sufficient and passes different steady state operation points. With finishing the
parametrization, the process repeats for the next insufficiently parametrized
model functionality until the overall model matches the expected behavior.

Fig. 2-2 Online Parametrization Workflow

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ETAS LABCAR-MODEL Family

2.3 Technical Aspects

This section comprises various technical points.

2.3.1 LABCAR Port Blocks

To enable communication with the LABCAR hardware as well as to connect to
other simulation models in the LABCAR-IP, appropriate interfaces are neces-
sary for Simulink modules. Instead of the Simulink inputs and outputs so-called
LCInports and LCOutports are used for this purpose. After the installation of
LABCAR-OPERATOR, these ports are available in the Simulink library. Simulink
based LABCAR-MODEL products provide already various LCPorts for a faster
integration. For further information about the Simulink integration in LABCAR-
OPERATOR products, see [1].

Fig. 2-3 LCInports and LCOutports

LCPorts are multifunctional interfaces, which can be of great benefit during the
closed-loop deployment. They provide the following key features:

Access:
Each LCPort is accessible via the workspace of LABCAR-EE.

Logging:
Signal traces can be generated using the Datalogger functionality of LABCAR-
EE.

Manipulation:
Manual signal manipulation is possible by overwriting the current signal value.

Stimulation:
Automatic signal manipulation is possible using the Signal Generator of LAB-
CAR-EE by overwriting the current signal value.

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ETAS LABCAR-MODEL Family

Simulink Simulink LCInport LCOutport

Inport Outport
Access No Yes Yes Yes
Logging No Yes Yes Yes
Manipulation No No Yes No
Stimulation No No Yes No

Tab. 2-1 Simulink Port and LCPort Functionality in LABCAR-OPERATOR and

COSYM

2.3.2 Simulink Model - Code Generation Process

LABCAR-OPERATOR
Simulink based simulation models have to go through a code generation pro-
cess when:
• You add a model to a project.
• You change the model *.mdl file.
• You explicitly request the code generation.
Since the code generation is crucial for the operation of LABCAR-MODEL, the
following section briefly describes the technical fundamentals.
During the code generation, the Simulink *.mdl file is translated into ANSI C-
code for a particular target, e.g. the ETAS RTPC. This translation takes place in
two steps. First, the model *.mdl file is translated into a model description file
*.rtw. The *.rtw file represents the original model in a high-level language
and is input for the subsequent "Target Language Compiler". In a second step,
C-code is specified for each Simulink block, based on a rule set described in a
particular *.tlc file. As result, the "Target Language Compiler" generates tar-
get compatible C-code. Simulink based LABCAR-MODEL products officially
support the code generation with the lcrt.tlc file that is shipped with LAB-
CAR-OPERATOR and COSYM.

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ETAS LABCAR-MODEL Family

Fig. 2-4 Code Generation Process for Simulink Models

NOTE
The grt.tlc file is not officially supported by LABCAR-MODEL products.

NOTE
The generated code may differ depending on the MATLAB versions, although
the same *.tlc file is used. In most of such cases it effects the representa-
tion of model parameters in LABCAR-EE.

COSYM
Unlike LABCAR-OPERATOR where the Simulink code generation is re-triggered
during every build, COSYM uses the already built sources of Simulink models. If
any modifications are needed in a Simulink model, the corresponding changes
need to be transferred to C-code using the following procedure.
To modify a Simulink model
1. Open the "Simulink model properties" view in COSYM with a
double click on the Simulink model.

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ETAS LABCAR-MODEL Family

2. Browse to the *.mdl file and double click on it to open the

Simulink model in the MATLAB®/Simulink® tool.

3. Make the necessary changes or updates to the model.

4. Perform the code generation by clicking on Run in the MAT-
LAB/Simulink tool. Select the lcrt.tlc target in the configu-
ration of the Simulink model.

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ETAS LABCAR-MODEL Family

5. Now in COSYM, right click on the Simulink model and perform

an update of the sources using the "Update model" pop-up
menu item.

2.3.3 MEX File Version Information

The MATLAB S-Functions included in the LABCAR-MODEL products carry an
embedded version information. For accessing the version information of a spe-
cific S-Function, its file extension has to be changed from mexw64 to dll.
Afterwards, it becomes accessible by right-clicking the file and opening the
"Properties" window of this file. The version information (cf. Fig. 2-5) is listed in
the "Details" tab of the properties dialog.

NOTE
Please consider this version information when sending an error report about
a single S-Function.

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ETAS LABCAR-MODEL Family

Fig. 2-5 Exemplary Version Information for an S-Function

2.3.4 Mapping External Files for HiL Execution

All Simulink-based LABCAR-MODEL products use pre-compiled binaries for the
execution. For running a model in Simulink on a Windows OS, according
dynamic link libraries (*.dll) and Mex-Functions (*.mexw64) are available in
each model folder. For the real-time execution on an RTPC, equivalent binaries
are available as object files (*.o) or as static link libraries (*.a). The following
section describes how to use these *.a and *.o files to build a COSYM or
LABCAR-OPERATOR project for the HiL execution.
In addition, each Simulink-based model product comes with the following files
for the HiL execution:
• libChecker.a
Mandatory file for licensing
• libLicenseChecker.a
Mandatory file for licensing
• <Mex-Function>.o
Mex-Function object code for each S-Function used by the model
All given *.a and *.o files in the model folder must be added as external
dependencies to the COSYM or LABCAR-OPERATOR project. COSYM and LAB-
CAR-OPERATOR offer the option to reference additional sources or binaries for
a model by using the "External Files" option. A detailed step-by-step guide is

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ETAS LABCAR-MODEL Family

given in section "Model Management", in the COSYM User Guide [6]. Ensure
that all required *.o files for the model and all *.a files for the licensing are
added.

NOTE
The project items folder contains already pre-configured Simulink models.
They include a file ExternalFiles.xml, which is parsed by COSYM or
LABCAR-OPERATOR as reference file when integrating the model directly
from the project items folder. All required external files in the
ExternalFiles.xml file are automatically set. This is also used in section
4.1.1, 5.1.1 and 7.1.1 for the corresponding creation of example projects.

2.4 LABCAR-MODEL Based FMUs

Starting with V4.3, the LABCAR-MODELs include a workflow to export LCRT-
compatible Simulink models as Function Mock-up Units (FMUs). In this way,
they can be used in COSYM-SiL or any other co-simulation tool, which supports
FMI-based model integration.
For keeping the compatibility with LABCAR-OPERATOR, the models continue to
use LC-Inports and LC-Outports. These ports serve as interface to the simula-
tion in the RTPC via LABCAR-EE. They need to be replaced by standard Sim-
ulink ports at the root level, before the FMU generation can take place. To this
end, an FMU exporter tool is introduced which facilitates the conversion of Sim-
ulink based LABCAR-MODELs to FMI 2.0 compatible FMUs.
The following table shows the LABCAR-MODEL products, the FMI version, and
the supported targets:

LABCAR-MODEL FMI 2.0 for Co-Simulation FMI 2.0 for Model Exchange
Product
LABCAR-MODEL-ICE Win64 -
LABCAR-MODEL-VVTB Win64 -
LABCAR-MODEL-FC Win64 -
LABCAR-MODEL_PMSM - -

2.4.1 FMU Exporter Tool

FMU Exporter is a MATLAB based command line interface tool that provides an
API to migrate LCRT-compatible Simulink models to FMUs. The tool abstracts
the functionality provided by FMI-Kit for the generation of FMUs.
The following phases are involved in translating a Simulink model to FMU:
• To identify and replace LC-Ports with Standard Simulink ports at root
level
• To locate the S-function dependencies for the models, which are needed
for the code generation
• To perform the code generation using the GRT-FMI target file of FMI-Kit.
The FMU Exporter tool is installed in a common location along with product
installers:

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ETAS LABCAR-MODEL Family

C:\Program Files\Common Files\ETAS\LABCAR-

MODEL\4.3\FMUExporter\

NOTE
Before using this FMU Exporter tool, install FMI-Kit (section 2.4.2 “FMIKit-
Simulink Library” on page 23).

The following methods are provided by the FMU exporter tool:

• LABCARMODEL.ExportAsFmu()
• LABCARMODEL.ExportAsFmuWithConfig()
• LABCARMODEL.CreateExportConfigurationTemplate()
• LABCARMODEL.ReplaceLabcarPorts()

ExportAsFMU
LABCARMODEL.ExportAsFmu(sourceModelFilePath,
targetFmuFilePath)
The function ExportAsFmu creates an FMU from a LABCAR-MODEL Simulink
model. The specified model is exported with default code generation settings.
The function ExportAsFmu requires two input arguments as the following
parameters.
• sourceModelFilePath (char array(1,:)) -
is the file path to the existing *.mdl model file, which shall be exported.
Both absolute paths and relative paths are accepted, as well as plain file
names, which can be found on the MATLAB path.
• TargetFmuFilePath (char array(1,:))
is the file path to which the generated *.fmu model file shall be saved.
A folder path is not sufficient, a file name is expected as part of the path.
Both absolute paths and relative paths are accepted, as well as plain file
names, which are relative to the current working folder. If it already
exists, it will be overwritten.
Find some examples in the following:
– LABCARMODEL.ExportAsFmu('VVTB.mdl', 'VVTB.fmu')
– LABCARMODEL.ExportAsFmu('C:\Program
Files\ETAS\LABCAR-MODEL\V4.2.0\VVTB\Simulink
Models\VVTB_MT\VVTB.mdl',
'C:\Temp\MyVVTBFMU.fmu')

To show the help text for this function in MATLAB

1. Type the command help LABCARMODEL.ExportAsFmu.
The help information appears directly in the MATLAB com-
mand line window.
or
1. Type the command doc LABCARMODEL.ExportAsFmu.
The help information appears in a separate HTML page.

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ETAS LABCAR-MODEL Family

ExportAsFmuWithConfig
LABCARMODEL.ExportAsFmuWithConfig(sourceModelFilePath,
targetFmuFilePath, configMFilePath)
The function ExportAsFmuWithConfig creates an FMU from a LABCAR-
MODEL Simulink model with custom code generation settings. These are
applied from a previously generated configuration file.
The function ExportAsFmuWithConfig requires three input arguments as
the following parameters:
• sourceModelFilePath (char array(1,:))
is the file path to the existing *.mdl model file, which shall be exported.
Both absolute paths and relative paths are accepted, as well as plain file
names that can be found on the MATLAB path.
• targetFmuFilePath (char array(1,:))
is the file path to which the generated *.fmu model file shall be saved.
A folder path is not sufficient, a file name is expected as part of the path.
Both absolute paths and relative paths are accepted, as well as plain file
names, which are relative to the current working folder. If it already
exists, it will be overwritten.
• configMFilePath (char array(1,:))
is the file path to the existing export configuration *.m file, which shall be
applied. A matching configuration file can be created using the function
LABCARMODEL.CreateExportConfigurationTemplate. Both
absolute paths and relative paths are accepted, as well as plain file
names that can be found on the MATLAB path.
Find some examples in the following:
– LABCARMODEL.ExportAsFmuWithConfig('VVTB.mdl',
'VVTB.fmu', 'MyVVTBExportConfig.m')
– LABCARMODEL.ExportAsFmuWithConfig('C:\Program
Files\ETAS\LABCAR-MODEL\V4.2.0\VVTB\Simulink
Models\VVTB_MT\VVTB.mdl',
'C:\Temp\MyVVTBFMU.fmu',
'C:\Temp\MyVVTBExportConfig.m')

To show the help text for this function in MATLAB

1. Type the command
help LABCARMODEL.ExportAsFmuWithConfig.
The help information appears directly in the MATLAB com-
mand line window.
or
1. Type the command
doc LABCARMODEL.ExportAsFmuWithConfig.
The help information appears in a separate HTML page.

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ETAS LABCAR-MODEL Family

CreateExportConfigurationTemplate
LABCARMODEL.CreateExportConfigurationTemplate(sourceMode
lFilePath, targetConfigMFilePath)
The function CreateExportConfigurationTemplate creates a configu-
ration file, which can be modified by the user and which can subsequently be
used for the function ExportAsFmuWithConfig to generate an FMU with
custom code generation options.
The function CreateExportConfigurationTemplate requires two input
arguments as the following parameters:
• sourceModelFilePath (char array(1,:))
is the file path to the existing *.mdl file, which shall be exported subse-
quently. Both absolute paths and relative paths are accepted, as well as
plain file names that can be found on the MATLAB path.
• targetConfigMFilePath (char array(1,:))
is the file path to which the generated *.m configuration template shall
be saved. A folder path is not sufficient, a file name is expected as part
of the path. Both absolute paths and relative paths are accepted, as well
as plain file names which are relative to the current working folder. If it
already exists, it will be overwritten.
Find some examples in the following:
– LABCARMODEL.CreateExportConfigurationTemplate('VVT
B.mdl', 'MyVVTBExportConfig.m')
– LABCARMODEL.CreateExportConfigurationTemplate('C:\
Program Files\ETAS\LABCAR-
MODEL\V4.2.0\VVTB\Simulink
Models\VVTB_MT\VVTB.mdl',
'C:\Temp\MyVVTBExportConfig.m')

To show the help text for this function in MATLAB

1. Type the command
help LABCARMODEL.CreateExportConfigurationTe
mplate.
The help information appears directly in the MATLAB com-
mand line window.
or
1. Type the command
doc LABCARMODEL.CreateExportConfigurationTem
plate.
The help information appears in a separate HTML page.

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ReplaceLabcarPorts
LABCARMODEL.ReplaceLabcarPorts(sourceModelFilePath,
targetModelFolderPath)
The function ReplaceLabcarPorts removes LABCAR-HiL dependencies
(LC-Inports, LC-Outports) from a LABCAR-MODEL Simulink model and replaces
them with From\Goto blocks.
The function ReplaceLabcarPorts requires two input arguments as the fol-
lowing parameters:
• sourceModelFilePath (char array(1,:))
is the file path to the existing *.mdl model file, which shall be exported.
Both absolute paths and relative paths are accepted, as well as plain file
names that can be found on the MATLAB path.
• targetModelFolderPath (char array(1,:))
is the folder path to which the modified model shall be saved. The folder
does not need to exist, but shall be empty if it does. Existing files in the
folder may be overwritten. Both absolute paths and relative paths are
accepted.
Find some examples in the following:
– LABCARMODEL.ReplaceLabcarPorts('VVTB.mdl',
'MyModifiedModelFolder')
– LABCARMODEL.ReplaceLabcarPorts('C:\Program
Files\ETAS\LABCAR-MODEL\V4.2.0\VVTB\Simulink
Models\VVTB_MT\VVTB.mdl',
'C:\MyModifiedModelFolder')

To show the help text for this function in MATLAB

1. Type the command
help LABCARMODEL.ReplaceLabcarPorts.
The help information appears directly in the MATLAB com-
mand line window.
or
1. Type the command
doc LABCARMODEL.ReplaceLabcarPorts.
The help information appears in a separate HTML page.

2.4.2 FMIKit-Simulink Library

FMIKit-Simulink is an open source Simulink library to import and export Func-
tion Mock-up Units (FMU) based on FMI V1.0 and V2.0 for Model Exchange and
Co-Simulation.
FMU Exporter uses this library for exporting the LABCAR-MODELs as FMUs. To
use the FMU Exporter tool, the latest version of FMIKit-Simulink library V2.9 is
needed.
For additional information and the download of the FMIKit-Simulink library,
please refer to the official "GitHub" page
https://github.com/CATIA-Systems/FMIKit-Simulink .

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ETAS LABCAR-MODEL Family

To use the FMU Exporter

1. Download FMIKit 2.9 from the FMIKit download link.
2. Extract it to a folder of your choice.
3. Refer to FMIKit Quick start to complete the FMI-Kit setup in
MATLAB.

LABCAR-MODEL V4.3 - User Guide 24

ETAS Installation

3 Installation
This section contains information on the scope of delivery and on how to pre-
pare for the installation.

3.1 User Privileges Required for Installation

You must have administrator privileges to install products of LABCAR-MODEL
on a PC. If in doubt, ask your system administrator.

3.2 Contents of the DVD

The products of LABCAR-MODEL are delivered as a DVD with the following con-
tents:
• ETAS_Safety_Advice.pdf
• Release_Notes.pdf
• Documentation:
Contains the User's Guide for LABCAR-MODEL products and Open
Source Scan (OSS) attribution documents.
• Installation:
Contains installer executable including all required installation packages.

3.3 Program Installation

This section describes how to install LABCAR-MODEL products.
1. Insert the product DVD in your DVD-ROM drive.
The DVD-Browser is launched.
2. Run Installation/setup.exe to start the installer manually.

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ETAS Installation

3. Click Next and follow the instructions of the installation wiz-

ard.
4. To complete the installation click Finish.

3.4 Contents of the Installation

The contents of the installation consists of the following:
• Simulink Models
There are Simulink models including compiled S-Functions in the form of
*.mexw64 files for Microsoft Windows and *.o files for ETAS RTPC.
For the integration into LABCAR-OPERATOR or COSYM projects, use the
Simulink models bundled as project items instead of the pure Simulink
models in this area of the installation. You find the description in the sec-
tion “Project Items” on page 26.
• FPGA Models
There are FPGA programming file (*.euf) and interface description
files (*.adf) for flashing the ES5340.2.
• Project Items
Project items are bundles of supplementary items for creating projects
in LABCAR-OPERATOR or COSYM. The items are tailored to the afore-
mentioned products for simple integration into new or existing LABCAR
projects.
Items in the subfolder LCO are compatible to LABCAR-OPERATOR, items
in the subfolder COSYM are compatible to COSYM.
Some items are specific to individual model variants as indicated by sub-
folder names. Inside these variant subfolders, individual items are again
categorized.
The items comprise the following:
– Simulink models
You find Simulink models inside the mdl subfolders, which are pre-
pared for direct import to LABCAR-OPERATOR or COSYM. The same
model variants are available here as described in the section “Sim-
ulink Models” on page 26.
– C-modules
You find C-modules inside the cmod subfolders, which can be helper
functions for initializing ambient conditions, for example.
– Connection files
You find connection files inside the conn subfolders, which help in
connecting different models, e.g. LABCAR-MODEL-VVTB and LAB-
CAR-MODEL-ICE, and C-modules to each other.
– Layers
You find layers inside the gui subfolders. They can be added to an
experiment in LABCAR-EE to provide an intuitive user interface with
handy controls for commonly used parameters and interesting
observables.
– Images
You find images inside the img subfolders. They are required for the
supplied experiment layers, which are located inside the gui subfold-
ers, to work as expected.

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ETAS Installation

– Mapping files
You find the mapping files inside the mapping subfolders. They pro-
vide abstractions for signals inside a model and are required for
experiment layers, which are located inside the gui subfolders, to
work as expected.
– RT-plugins
You find the RT-plugins inside the rtp subfolders. They provide addi-
tional functionality required for experiment layers, which are located
inside the gui subfolders, to work as expected.
– Specific user-data
You find the specific user data inside the userdata subfolders.
When creating a project, choose the items from the subfolder for the
desired model variant. Project items for different models variants differ
from each other and are not interchangeable. For example, connection
files found in the project items of LABCAR-MODEL-VVTB differ between
the automatic transmission model variant (VVTB_AT) and the manual
transmission model variant (VVTB_MT).
You can find more information on how to use the specific project items
delivered with LABCAR-MODEL products in the product-specific sec-
tions of this User's Guide.
For general information about items like layers, mapping files, connec-
tion files, etc., and how to work with them please refer to [1].
• LicenseConfigurationInfo:
These are files for the ETAS License Manager.
• Example Project:
Pre-built example projects for LABCAR-OPERATOR are available in the
LCO subfolder of this area. Example projects for COSYM may be found
in the COSYM subfolder for products supporting it.
• Documentation:
This area contains the User's Guide, Safety Advices as well as individual
Model Reference Guides.

NOTE
Please do not open or manipulate the files in the installation folder directly.
Instead create a working copy from the installation folder in a location of your
choice.

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ETAS LABCAR-MODEL-VVTB

4 LABCAR-MODEL-VVTB
ETAS LABCAR-MODEL-VVTB is the virtual vehicle test bench. On the one hand
it serves as the top-level vehicle model and allows for an easy integration of all
those sophisticated, domain-specific component models that you need to
describe the full SUT. On the other hand it provides simplistic default imple-
mentations for all subsystems, where no sophisticated component models are
needed.

4.1 Project and Experiment Creation

In the following, step-by-step guides describe the generation of a COSYM proj-
ect or a LABCAR-OPERATOR project using LABCAR-MODEL-VVTB. For the exe-
cution of the project, no physical ECU is needed. Instead, a SoftECU controls
the engine model. The project to be created contains a manual transmission
vehicle model that is predefined by the VVTB_MT model configuration.

4.1.1 Project Creation in COSYM

This section addresses qualified personnel with knowledge in using COSYM. If
you do not have any experience in using COSYM, please read first [6].
For the manual project creation using LABCAR-MODEL-VVTB with COSYM fol-
low the steps described in this section.
To set up the COSYM project
1. Open the COSYM application.
The COSYM application can already have a open project. In
this case
2. Click File  New Project.
or
If there is no previous project loaded,
- Click Create new project.
3. Choose the location for the project.and name the project.
4. Click Create.

NOTE
Refer to section 7.1 in [6] for additional help regarding the project creation in
COSYM.

> The "Library" section of the project is empty to start with. A

default system is created with the name "System" and auto-
matically mapped to "HiL_Target".
To add a hardware module to the system
1. Double click on the pane "System".
2. Expand "System"
3. Right click on "HiL_Target" and select "Create RTIO module"
from the drop-down menu.

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> The "System" shows the added hardware module in "Diagram"

view.
The full vehicle model consists of a single Simulink module. This module also
contains driver, environment, vehicle, and SoftECU, which mimics the behavior
of an EMS.
To add a Simulink module
1. In the "Library" pane, right click on the "Control" folder and
choose "Import Model".
2. Under "Source of the model to be imported", click on Browse
button.
3. Select the LMD file "VVTB.lmd", which internally refers to
model configuration VVTB.mdl. The corresponding LMD file
"VVTB.lmd" is located in the installation folder:
.\VVTB\Project Items
\COSYM\VVTB_MT\mdl\Simulink_VVTB\src\VVTB_LA
BCAR_rtw.
4. Click on the Import button.
The model "VVTB" is added to the "Library" under the "Control"
folder.
5. Drag and drop the "VVTB" model from the "Library" pane
- to the "Diagram" area of the '"System"
- and to the "Units" folder of "System" under the "Systems"
pane.
> The "System" shows the added module in the "Diagram" view.

NOTE
The Simulink model references additional dependencies by using the
ExternalFiles.xml. Please see section “Mapping External Files for HiL
Execution” on page 18 for further details.

By default, the SoftECU is not connected to the vehicle or driver model,

although it is part of the already integrated Simulink module VVTB.mdl. Pre-
defined connection files couple the SoftECU and the vehicle model internally.
The following connection files have to be added:

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• BodyComponents_Basic-CU_EMS.xml
• Combustion_Gasoline-CU_EMS.xml
• CU_EMS-Combustion_Gasoline.xml
• CU_EMS-Vehicle.xml
• CU_Testbed-VehicleDynamics_Longitudinal.xml
• Driver_Longitudinal-CU_Testbed.xml
• Driver-CU_EMS.xml
• Driver-CU_TCU_MT.xml
• Drivetrain_Longitudinal-CU_EMS.xml
• Drivetrain_Longitudinal-CU_TCU_MT.xml
• Drivetrain_Longitudinal-CU_Testbed.xml
These files are located in the installation folder at
.\VVTB\Project Items\COSYM\VVTB_MT\conn.

To add connection files

1. Open the "Connections" view available at the bottom of the
opened "System".
2. Click on the "Import connections" icon.
3. Select each XML file mentioned above.
4. Click on Import to import connections from each file.
5. Repeat the steps 1 to 4 for all the connection files mentioned
above.

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> After the connection files are added, the necessary connec-
tions are established between the VVTB and SoftECU. They
are visible in the "Connections" view.

Fig. 4-1 COSYM Connections View for VVTB

Fig. 4-2 COSYM Diagram View with Connections for VVTB

NOTE
Check each connection file and ensure that you added all connection files.
Otherwise, the COSYM project might not work properly.

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OS Configuration
Via the "Deployment" view, you can organize the processes of COSYM mod-
ules. For Simulink modules, the order of execution and the selection of a proper
step size is important. By default, tasks are not auto-generated for Simulink
modules when adding them to the project. Please click on + Auto mapping to
automatically map the processes to tasks.

In addition to the model tasks, it is important to generate a process hook. The

RT-Plugins require such process hooks.
To add RT-Plugins:
1. Right-click on TaskDVEModel.
2. Choose Add Hook.
3. Name the hook Driver_RTPlugin.
4. Move this hook before the process
lcrt_OneStep_Outputs_VVTB.

All relevant modules to operate the vehicle and the engine model are available
and you can build a COSYM project.

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To build a COSYM project

1. Choose Project Build and Run.
2. Click Build and Run.

For more details about the Simulink code generation, refer to “Simulink Model -
Code Generation Process” on page 14.

4.1.2 Project Creation in LABCAR-OPERATOR

This section addresses qualified personnel with knowledge in using LABCAR-
OPERATOR. If you do not have any experience in using LABCAR-OPERATOR,
please read first [1].
For the manual project creation using LABCAR-MODEL-VVTB with LABCAR-
OPERATOR follow the steps described in this section.
To set up the LABCAR-OPERATOR project
1. Open the LABCAR-IP application.
2. Click File  New Project.
3. Choose the location for the file and name the project.
4. Use "RTPC" as "Target Name".
5. Click Finish.
> The project explorer contains an empty hardware configura-
tion.
The full vehicle model consists of a single Simulink module. This module also
contains driver, environment, vehicle, and SoftECU, which mimics the behavior
of an EMS.
To add a Simulink module
1. Choose Project  Add Module.
2. Select "Add Simulink (TM) Module".
3. Select "Use existing Simulink (TM) Model (will be copied)".

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4. Select the model configuration VVTB_MT. The corresponding

model VVTB.mdl is located in the install folder
.\VVTB\Project Items\LCO\VVTB_MT\mdl\
Simulink_VVTB\src.
5. Activate the checkbox "Copy Model Directory into Project".
6. Click Finish.
> The Project Explorer shows the added module..

NOTE
The Simulink model references additional dependencies by using the
"ExternalFiles.xml". Please see section “Mapping External Files for HiL
Execution” on page 18 for further details.

Per default, the SoftECU is not connected to the vehicle or driver model,
although it is part of the already integrated Simulink module VVTB.mdl. Pre-
defined connection files couple the SoftECU and the vehicle model internally.
To add connection files
1. Open "Connection Manager" and right-click.
2. Select Import Connection.
3. Import each connection file stored in the install folder at
.\VVTB\Project Items\LCO\VVTB_MT\conn.
> After the connection files are added, many connections are vis-
ible in the "Connection Manager".

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NOTE
Check each connection file and ensure that you added all connection files.
Otherwise the model might not work properly.

OS Configuration
Via the "OS Configuration" tab, you can organize the processes of LABCAR-
OPERATOR modules. For Simulink modules, the order of execution and the
selection of a proper step size is of importance. Per default, proper tasks for the
Simulink model are auto-generated when adding the module to the project.

In addition to the model tasks, it is important to generate a process hook. The

RT-Plugins require such process hooks.
To add RT-Plugins
1. Right-click on TaskDVEModel.
2. Choose "Add Hook".
3. Name the hook Driver_RTPlugin.

> All relevant modules to operate the manual transmission vehi-

cle model VVTB_MT are available.
As next step, you can build the LABCAR-OPERATOR project.

NOTE
Be sure to select the proper MATLAB version using the MATLAB Version
Selector. See [2].

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To build a LABCAR-OPERATOR project

1. Choose Project Build.
2. Activate the check box for the VVTB module.
3. Click Build.

The build process performs the following basic steps:

• Simulink code generation on the host PC
• Transfer of the source code to RTPC
• Compilation of sources on RTPC
• Transfer of binaries back to the host PC
For more details about Simulink Code Generation, see “Simulink Model - Code
Generation Process” on page 14.

4.1.3 Experiment Creation

After the successful build of the project in COSYM or LABCAR-OPERATOR, you
can prepare the experiment for the first execution of the simulation model.
Starting point is an empty experiment.

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Mapping Files
"Mapping files" provide a possibility to simplify the signal handling in LABCAR-
EE. For LABCAR-MODEL-VVTB various signal mappings are predefined. This
allows a simple access to most important simulation signals without in-depth
knowledge of the model.
1. Open Experiment Explorer.
2. Add all mapping files located in the install folder at
.\VVTB\Project Items\LCO\VVTB_MT\mapping.

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NOTE
Ensure that the added mapping files are also activated.

Parameter Files
No parameter files are provided. The default values of the Simulink model are
used.

RT-Plugin
RT-Plugins are compiled c-code snippets, which can be added to an experiment
without the rebuild of the complete project. It is a tool to add user-defined func-
tionality to an experiment. The GUI of the example project uses a RT-Plugin to
extend the functionality of the default instruments of LABCAR-EE.
To add RT-Plugins
1. Open Experiment Explorer.
2. Add RT-Plugins located in the install folder at
.\VVTB\Project Items\LCO\VVTB_MT\rtp\Driver_
Instruments.

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After the RT-Plugin is added, it is also available in the RT-Plugin

tab of LABCAR-EE. Open it to check its availability.
3. Open RT-Plugins tab.

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NOTE
Each RT-Plugin requires a process hook for execution. Ensure that the pro-
cess hook "Driver_RTPlugin" is available in the OS-settings. See the paragraph
“To add RT-Plugins” on page 35.

Layers
The layer provides the basic interface to handle the vehicle model. It allows the
setting of the driver mode and the selection of predefined cycles. As prelimi-
nary step you can copy images for the layer from the installation folder.
To import layers
1. Copy images from
.\VVTB\Project Items\LCO\VVTB_MT\img.
2. Create the target folder if it does not already exist in the Exper-
imentation folder and name it as "Image_Files".
3. Paste the images copied in step 1.
4. Import the Driver.layer file as located in
.\VVTB\Project Items\LCO\VVTB_MT\gui.

> After the successful import of the Driver layer, basic dash-
boards for handling the VVTB model exist.

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NOTE
All predefined instruments use mapped signals provided by the mapping
files. For proper execution, ensure that all mapping files are added to the
experiment.

NOTE
To extend the functionality of the standard instruments, so called RT-Plugins
are used. Ensure that the pre-compiled RT-Plugins are added to the experi-
ment.

NOTE
Consider that only default LABCAR-EE instruments are used. The layer can be
adapted individually to your needs.

All required artifacts for the first execution of the VVTB_MT model are added to
the experiment. With that, the experiment is ready for the download to the
RTPC and the simulation. The section “Getting Started with the Tutorial Project”
on page 42 describes the handling of the simulation model in more detail.

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4.2 Getting Started with the Tutorial Project

The following tutorial gives an introduction on how to use LABCAR-MODEL-
VVTB. Within this tutorial LABCAR-MODEL-VVTB is used to represent a vehicle
with manual transmission. A physical control unit is not required, since the
SoftECU of LABCAR-MODEL-VVTB will be used to control the simple combus-
tion engine model.
The tutorial project is located in .\Example Project\LCO\01_VVTB_MT.

NOTE
Please do not open or manipulate the example project in the installation
folder directly. Instead, copy the example project from the installation folder
to a location of your choice.

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4.2.1 Overview
The "Driver" tab in LABCAR-EE contains four windows as shown in the following
figure.

Driver Control Settings

Menu to set the operation mode of the longitudinal driver. Especially, following
settings are available:
• Select Driver Mode, e.g. velocity tracking or manual operation
• Select Cycle
• Select inputs for accelerator, clutch, brake, and gear
• Set manual values for accelerator, clutch, brake, and gear

Dashboard
The dashboard shows the current status of the vehicle. It provides typical nee-
dle instruments for engine speed and vehicle velocity. Furthermore, it presents
the driver output, i.e. the clutch, accelerator, and brake pedal position as well as
the gear lever position.

Testbed Settings
LABCAR-MODEL-VVTB provides two engine testbed modes to bring the engine
in a particular operation point defined by engine speed and engine torque. The
testbed settings allow the parametrization of the desired operation point.

Simulation
Two oscilloscopes provide information about desired and measured engine
and vehicle speed.

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NOTE
If a different MATLAB version is used than defined in the release note of LAB-
CAR-MODEL, the structure of the LABCAR-EE workspace might differ.

4.2.2 Cycle Driving

Cycle driving is one of the most common tests in ECU development. The fol-
lowing guide shows how to drive a pre-defined cycle and a user-defined cycle
with LABCAR-MODEL-VVTB.

4.2.2.1 Predefined Cycles

LABCAR-MODEL-VVTB provides a set of predefined cycles. They can be
accessed by the driver dashboards. In general cycle driving can be defined in
two ways:
• For following a pure velocity profile, select:
Set Driver Mode  Target Speed - Internal Gear (MT)
• For following a velocity and gear profile, select:
Set Driver Mode  Target Speed - External Gear (MT)

In the given example, the driver determines the gear.

• After that, choose the desired cycle in the drop-down menu:

The Target Speed mode of the driver is automatically set to Cycle.

Herewith, the driver's reference speed is that one coming from the
cycle.

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NOTE
When the mode Target Speed - Internal Gear (MT) is set, then no manual
input for accelerator, brake, or clutch pedal position is possible. The driver
model regulates all pedal positions.

4.2.2.2 User-Defined Cycle

User-defined cycles are often used for testing individual functions of an ECU.
Such individual cycles are defined via workspace parameters or the signal gen-
erator of LABCAR-EE.

Via Setting Workspace Parameters

The driver model of LABCAR-MODEL-VVTB provides a dedicated location for
user-defined cycles. When using that approach, set the desired driver mode.
• For following a pure velocity profile, select:
Set Driver Mode Target Speed - Internal Gear (MT)
• For following a velocity and gear profile, select:
Set Driver Mode  Target Speed - External Gear (MT)

• After that, choose the user cycle in the drop-down menu:

Set Cycle Mode  Usr

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The user cycle definition is set as 1-D velocity curve over the simulation time.
The 1-D curve is accessible via the workspace.
To display the 1-D curve
1. Search cycle
2. Drag & Drop D_TestCycles__UserdefinedCurve

3. Edit D_TestCycles__UserdefinedCurve

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The user-defined cycle is defined by the parameter

D_TestCycles__UserdefinedCurve, which can be
adapted accordingly.
4. Start the simulation.
> The user-defined cycle will be followed by the driver.

Via Signal Generator

In the following, a user-defined cycle is created using the "Signal Generator" of
LABCAR-EE. Initially, set the desired driver mode.
• For following a pure velocity profile, select:
Driver Mode Target Speed - Internal Gear (MT)

The driver has individual stimulation inputs for the reference speed. Here, the
External stimulation input is selected for connecting the "Signal Generator".
Target Speed External

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Subsequently, a user-defined cycle with the "Signal Generator" is generated. For

further information about the "Signal Generator" see [1].

At that point, a signal generator signal is given. Furthermore, the driver is look-
ing for the reference speed coming from the external stimulation input. The last
step is connecting the external stimulation input with the "Signal Generator".
• Search v_target_external.
• Right-click Signal Trace.

For the traced LCInport, set following options:

• "Mode" SIGNALGENERATOR

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• "Signal Description" SignalGenerator/…

So the LCPort the driver is looking at is connected to the "Signal Genera-

tor".
• Start the simulation and the driver will follow the user-defined cycle.

4.3 Signal Interface

All of the presented interfaces connect driver, SoftECU, and vehicle in the exam-
ple project of the section “Project and Experiment Creation” on page 28. They
are the minimal interfaces that a SoftECU or a physical ECU has to satisfy when
running LABCAR-MODEL-VVTB.
The model reference guide of LABCAR-MODEL-VVTB provides the complete
documentation of the physical interfaces of each S-Fcn and sub-system.

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4.3.1 Driver

Inputs
Name Type Unit Description
- - - -

Outputs
Name Type Unit Description
b_Ignition Bool - Driver ignition request
b_Starter Bool - Driver starter request
i_Gear Int - Desired gear
r_Accelerator_0_1 Double - Accelerator pedal posi-
tion
r_Brake_0_1 Double - Brake pedal position
r_Clutch_0_1 Double - Clutch pedal position

4.3.2 SoftECU

Inputs
Name Type Unit Description
Starter Bool - Received starter signal
n_Engine Double rpm Measured engine speed
M_Ind_In Double Nm Measured induced
engine torque
M_Drag_In Double Nm Measured engine drag
torque
M_CombEngine Double Nm Effective engine torque
N_ThrottlePlateOpen- Double % Measured throttle plate
ing_r_0_100 position
In_Gearbox_Shifting Bool - Flag indicating active
gear box shifting
Ignition Bool - Driver ignition flag
Gear Int - Current gear
Clutch Double - Clutch pedal position
Brake Double - Brake pedal position
Battery Bool - Battery on / off
Accelerator Double - Accelerator pedal posi-
tion

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Outputs
Name Type Unit Description
Accelerator_Out Double - Processed accelerator
pedal position
Brake_Out Double - Processed brake pedal
position
Clutch_Out Double - Processed clutch pedal
position
Gear_Out Int - Processed gear
Ignition_Out Bool - Processed ignition flag
M_Target_fast_Out Double Nm Desired torque for fast
requests
M_Target_slow_Out Double Nm Desired torque for slow
re-quests
Starter_Out Bool - Processed starter flag
SignalBit_slow_out Bool - Flag indicating fast
torque request
SignalBit_fast_out Bool - Flag indicating slow
torque request

4.3.3 Vehicle/Drivetrain

Inputs
Name Type Unit Description
CU_Gear Int - Requested gear

Outputs
Name Type Unit Description
Actual_Gear Int - Current gear
GearboxShifting Bool - Flag indicating active
gear box shifting
n_Engine Double rpm Calculated engine speed

4.3.4 Vehicle/CombustionEngine

Inputs
Name Type Unit Description
SignalBit_slow Bool - Flag indicating slow
torque request
SignalBit_fast Bool - Flag indicating fast
torque request
M_Target_slow Double - -
M_Target_fast Double - -

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Outputs
Name Type Unit Description
M_Drag Double Nm Calculated engine drag
torque
M_Engine Double Nm Calculated engine torque
M_Ind Double Nm Calculated induced
engine torque
M_Ind_Max Double Nm Calculated maximum
induced engine torque
ThrottlePlateOpen- Double - Throttle plate opening
ing_r_0_100

4.3.5 Driver/BodyComponents

Inputs
Name Type Unit Description
CU_Starter Bool - Starter status communi-
cated by CU
CU_Ignition Bool - Ignition status commu-
nicated by CU

Outputs
Name Type Unit Description
BatteryIsOn Bool - Battery status

NOTE
Interfaces of the physical subsystems, e.g., drivetrain, combustion engine or
chassis, are documented in the model reference guide of LABCAR-MODEL-
VVTB.

4.4 User Interface

The provided Graphical User Interface (GUI) for LABCAR-MODEL-VVTB con-
tains basic functionality to operate the vehicle model comfortably. The GUI
allows to select a driver mode and to define external trajectories to be followed
by the vehicle model. The driver mode defines the operational mode of the vehi-
cle model via its included model of a driver. Basic observables about the vehi-
cle's operation and state are presented graphically.

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4.4.1 Overview
The GUI consists of the 4 sections in the following figure:

A The section "Driver Control Settings" provides controls to operate the

vehicle. The available functionality depends on the chosen driver mode.
Driver modes are described in the section “Driver Modes” on page 54.
After selecting the driver mode, you can control the vehicle by interact-
ing with the available controls. The individual control elements are
described in the section “Controlling the Vehicle” on page 56.
B "Testbed Settings" are an extension of the Driver Control Settings to sim-
ulate the vehicle sitting on a roller dynamometer test bench. Testbed
Settings are enabled in specific Dyno driver modes only.
C The "Dashboard" presents the current engine speed and the vehicle
speed similar to a real car's cockpit. Additionally, the positions of the
clutch pedal, the brake pedal, the accelerator pedal and the gear lever are
shown. 0% indicates an untouched pedal, 100% indicates a fully pressed
pedal. Icon indicators of the starter's and the ignition's state comple-
ment the Dashboard. There are On/Off switches that enforce the activa-
tion of starter and ignition if set to On. If set to off, starter and ignition are
handled by the model.
D The section "Simulation" contains graphs of the engine speed and the
vehicle speed over time.

NOTE
The GUI uses standard instruments of LABCAR-EE and an open-source RT-
Plugin to extend the instruments' functionality. This can be used as template
for individual GUIs easily.

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For the GUI to function as expected, its RT-Plugin Driver_Instru-

ments.rtp and the mappings Driver_Instruments.txt need to be acti-
vated as described in the section “Project and Experiment Creation” on
page 28.

4.4.2 Driver Modes

The GUI's Driver Control Settings section contains a drop-down list labeled
Driver Mode. Using this drop-down list, you can select different driver modes or
switch between them:

Switching between driver modes changes the behavior of the vehicle's driver
model. Parts of the GUI are activated or deactivated depending on the selected
driver mode. This activation or deactivation of controls can take a fraction of a
second depending on the Windows host machine and LABCAR.
The following list describes the available driver modes, the resulting behavior of
the driver model and the available GUI control elements in every mode. These
individual control elements are explained in the section “Controlling the Vehicle”
on page 56.

Target Speed - Internal Gear (MT)

This mode is intended for the use in the model variant VVTB-MT, the variant
with manual transmission. When this mode is selected, all GUI control ele-
ments except Target Speed are disabled. Using the slider or the input field, a
target speed can be defined. The driver will accelerate or decelerate the vehicle
to the defined target speed. It will handle the accelerator, brake and clutch ped-
als as well as shift gears automatically.

Target Speed - Internal Gear (AT)

This mode is intended for the use in the model variant VVTB-AT, the variant
with automatic transmission. The GUI functionality is identical to Target
Speed - Internal Gear (MT).

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Target Speed - External Gear (MT)

This mode is similar to the Target Speed - Internal Gear modes. The
model will still operate the pedals automatically to reach the user-defined tar-
get speed. However, the model-internal determination of the appropriate gear
is disabled. The driver has control over the gear lever at the right of the GUI
section shown above. All other controls except target speed and gear are dis-
abled since they are handled by the driver model.

Manual Gas and Brake - Automatic Gear

In this mode, the driver model does not operate the accelerator and the brake.
Instead, the user has control over these two pedals. However, the driver model
still shifts gears and operates the clutch automatically. This driver mode oper-
ates the vehicle as if it was an automatic car.

Manual Gas, Brake, Gear, Clutch

This mode offers full manual control over all three pedals and the gear lever to
the user and deactivates the driver model.

NOTE
The engine is easily stalled in this mode because of the user-defined clutch
control.

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Dyno - Acc Control

This mode enables the GUI section "Testbed Settings". When switching to this
Dyno mode, the desired gear has to be chosen. Under "Set point", you can
define a desired engine speed in the "n_Eng " row. The driver model will then
accelerate the vehicle as necessary to reach the set point engine speed. This
may take a few seconds. The green light "Dyno I" indicates that the engine
speed approaches the set point. An additional counter-torque can be applied
manually as well in the same "Set point" column in the "Counter-torque" row.

NOTE
Before activating this mode, the vehicle needs to have an appropriate speed
first, because it relies on a manual gear choice. This can be achieved. e.g., by
using one of the "Target Speed" driver modes.

Dyno - Torque Control

This mode enables the GUI section "Testbed Settings". When switching to this
Dyno mode, the desired gear has to be chosen by the user, as well as a fixed
accelerator pedal position. Under "Set point", a desired engine speed can be
defined. The model will then apply counter torque on the rollers as necessary,
until the set point engine speed is reached. This may take a few seconds. The
green light "Dyno II" indicates that the engine speed approaches the set point.

NOTE
Before activating this mode, the vehicle needs to have an appropriate speed
first, because it relies on a manual gear choice. This can be achieved, e.g., by
using one of the "Target Speed" driver modes.

4.4.3 Controlling the Vehicle

The GUI provides individual control elements to reflect the controls that are
available in a real vehicle:
• accelerator pedal

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• brake pedal
• clutch pedal
• gear lever
Since LABCAR-MODEL-VVTB contains a complex driver model, which is able to
operate these elements automatically, interaction possibilities depend on the
selected driver mode. For the "Target Speed" driver modes, additional controls
are available instead of the pedals:
• Target Speed
• Cycle
The usage of these two controls is special and explained in the section “Driving
Test Cycles” on page 59.
A typical control element consists of:
• Input selector:
a drop-down list to select the input source of the control's value.
• Slider:
a graphical interaction method to change the control's value manually.
• Input field:
a decimal input field to change the control's value manually.

Input Selector
The drop-down list of every control element allows to select different input
sources for the control's value. Every interface possibility that LABCAR pro-
vides can be connected as input source and switched between, using the input
selector. The user can switch the input source at any time during the simula-
tion.
The available input sources are:

• Off
A control that is unavailable to the user in the selected driver mode is set
to Off. This option is not selectable by the user. You have to change the
driver mode to use the respective control. A control set to Off is either
controlled automatically by the driver model or unavailable in the
selected driver mode. It is set automatically by selecting the driver mode.
• Manual
A control that is available to the user in the selected driver mode is by de-
fault set to Manual. This option allows you to change the control's value
using the slider or the input field.

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• Stimulation
Each control element has a dedicated LCInport inside the model that can
be used as input source for the control's value. When the option
Stimulation is selected instead of Manual, the respective LCInport
in the model is used as input source instead of the GUI slider/input field.
This LCInport is intended for connection to a "SignalGenerator" or con-
nection to another module/model of the LABCAR project.
The LCInports of every control can be found in the LABCAR-EE Work-
space Elements tree under:
VVTB/ETAS_Virtual_Vehicle_Test_Bench/Driver/
Longitudinal/Driver Modes/User Input/
Selector_<ControlName>/<ControlName>_stim:

For more information on LCInports and SignalGenerators refer to [1].

• External
Like Stimulation, the option External uses an LCInport as input
source. It is available next to the Stimulation LCInport:

When the Stimulation LCInport is already connected to a SignalGen-

erator, this External LCInport could be used to connect to a hardware
controller or another controller as well. The drop-down option
External can then be used to switch the input source from Manual or
Stimulation to External "on-the-fly".

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Slider
The slider can be used to change the control's value using the mouse cursor.
For the accelerator, brake and clutch pedals, 0 represents an untouched pedal
and 1 represents a fully pressed pedal.
The slider's value is only respected by the model when the input selector is set
to Manual.

Input Field
The input field can be used to define a precise decimal value. The display is
rounded by default, but the number of displayed decimals can be changed
using the LABCAR-EE "Properties" window.
The input field's value is only respected by the model when the input selector is
set to Manual.

4.4.3.1 Driving Test Cycles

The driver model of LABCAR-MODEL-VVTB is able to follow predefined test
cycles or a user-defined test cycle without any user interaction. A test cycle is
defined as a target vehicle speed trajectory over time. The following test cycles
are available:
• ECE2
• ECE3
• F72
• F75
• J11
• J15
• Usr
Usr does not contain a test cycle by default. This allows you to define a test
cycle that can then be executed in the same fashion as the predefined test
cycles.
Test cycles can be executed when one of the Target Speed driver modes is
selected. The Target Speed's input selector is similar to the other controls' input
selectors, but offers the additional option Cycle:

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When "Target Speed" is set to Cycle, the drop-down list labeled "Cycle" can be
used to select one of the test cycles listed above. The driver will then drive that
test cycle.

NOTE
The functionality uses a model-internal clock, which starts running at simula-
tion start. To execute a test cycle from its start, it is recommended to select
the test cycle directly after simulation start.

When "Target Speed" is set to any other input source than Cycle, the drop-
down list "Cycle" is disabled and labeled Off. A previously selected test cycle
will be remembered when switching "Target Speed" back to Cycle.
The section “Getting Started with the Tutorial Project” on page 42 contains a
tutorial showing the process of defining and executing test cycles.

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5 LABCAR-MODEL-ICE
ETAS LABCAR-MODEL-ICE is a detailed model of an internal combustion
engine (ICE) and of its main subsystems. These are the combustion system,
the fuel system, the intake and exhaust system, and the aftertreatment system.
The model includes several preconfigured standard variants for Diesel, CNG,
and Gasoline engines.

5.1 Project and Experiment Creation

In the following, step-by-step guides describe the generation of a COSYM proj-
ect or a LABCAR-OPERATOR project using LABCAR-MODEL-ICE. For the execu-
tion of the project, no physical ECU is needed. Instead, a SoftECU controls the
internal combustion engine model. The project to be created contains the man-
ual transmission vehicle model LABCAR-MODEL-VVTB given by the VVT-
B_MT_ICE model configuration that is combined with the gasoline variant of
LABCAR-MODEL-ICE given by the ICE_G_1B_1Stg_DEMO model configuration.

5.1.1 Project Creation in COSYM

This section addresses qualified personnel with knowledge in using COSYM. If
you do not have any experience in using COSYM, please read first [6].
For the manual project creation using LABCAR-MODEL-ICE with COSYM follow
the steps described in this section.
To set up the COSYM project
1. Open the COSYM application.
The COSYM application can already have a open project. In
this case
2. Click File  New Project.
or
If there is no previous project loaded
- Click Create new project.
3. Choose the location for the project.and name the project.
4. Click Create.

NOTE
Refer to section 7.1 in [6] for additional help regarding the project creation in
COSYM.

> The "Library" section of the project is empty to start with. A

default system is created with the name "System" and auto-
matically mapped to "HiL_Target".
To add a hardware module to the system
1. Double click on the pane "System".
2. Expand "System"
3. Right click on "HiL_Target" and select Create RTIO module
from the drop-down menu.

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> The "System" shows the added hardware module in "Diagram"

view.
The full vehicle model as well as the internal combustion engine model consist
each out of a single Simulink module. This module also contains driver, envi-
ronment, vehicle, and SoftECU, which mimics the behavior of an EMS. It will
control the internal combustion engine model.
To add the virtual vehicle test bench model
1. In the "Library" pane, right click on the "Control" folder and
choose "Import Model".
2. Under "Source of the model to be imported", click on Browse
button.
3. Select the full vehicle model configuration VVTB_MT_ICE. The
according LMD file "VVTB.lmd", which internally refers to the
model configuration VVTB.mdl. The corresponding LMD file
"VVTB.lmd" is located in the installation folder:
.\VVTB\Project Items
\COSYM\VVTB_MT_ICE\mdl\Simulink_VVTB\src\VVT
B_LABCAR_rtw.
4. Click on the Import button.
The model "VVTB" is added to the "Library" under the "Control"
folder.
5. Drag and drop the "VVTB" model from the "Library" pane
- to the "Diagram" area of the '"System"
- and to the "Units" folder of "System" under the "Systems"
pane.
> The "System" shows the added module in the "Diagram" view.

NOTE
The Simulink model references additional dependencies by using the
"ExternalFiles.xml". Please see section “Mapping External Files for HiL
Execution” on page 18 for further details.

To add the internal combustion engine model

1. In the "Library" pane, right click on the "Control" folder and
choose "Import Model".

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2. Under "Source of the model to be imported", click on Browse

button.
3. Select the internal combustion engine model configuration
ICE_G_1B_1Stg_DEMO. The according LMD file
VTB_ICE_LC.lmd, which internally refers to model configura-
tion VVTB_ICE_LC.mdl. The corresponding LMD file
VVTB.lmd is located in the installation folder:
.\ICE\Project Items
\COSYM\ICE_G_1B_1Stg_DEMO\mdl\Simulink_VVTB_
ICE_LC\src\VVTB_ICE_LC_LABCAR_rtw.
4. Click on the Import button.
The model "VVTB_ICE_LC" is added to the "Library" under the
"Control" folder.
5. Drag and drop the "VVTB" model from the "Library" pane
- to the "Diagram" area of the '"System"
- and to the "Units" folder of "System" under the "Systems"
pane.
> The "System" shows the added module in the "Diagram" view.

NOTE
The Simulink model references additional dependencies by using the
"ExternalFiles.xml". Please see section “Mapping External Files for HiL
Execution” on page 18 for further details.

The internal combustion engine model requires initial environment conditions

for proper simulation. For this purpose, C-Code modules are used for tempera-
ture and pressure initialization.
The following C-Code modules have to be added:

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• Init_T_Ambient.lmd
Located in installation folder at
.\ICE\Project Items
\COSYM\ICE_G_1B_1Stg_DEMO\cmod\Init_T_Ambient
• Init_p_Ambient.lmd
Located in installation folder at
.\ICE\Project Items
\COSYM\ICE_G_1B_1Stg_DEMO\cmod\Init_p_Ambient

To add a C-Code module

1. In the Library pane, right click on the "Environment" folder and
choose "Import Model".
2. Under "Source of the model to be imported", click on the
Browse button.
3. Select the C-Code module's LMD file from the locations speci-
fied above.
4. Click on the Import button.
5. The C-Code model is added to the "Library" under the "'Environ-
ment" folder.
6. Open the "System" from the "Systems" pane by double click.
7. Drag and drop the C-Code model from the "Library" pane
- to the Diagram area of the "System".
- to the "Units" folder of "System" under the "Systems" pane.
8. Repeat the steps 1 to 7 for the 2 C-Code modules listed above.

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> The "System" shows the added C-Code module in the "Dia-
gram" view.

By default, no model connections are established. For example the SoftECU is

not connected to the vehicle, driver model or engine model, although it is part
of the already integrated Simulink module VVTB.mdl. Pre-defined connection
files couple the vehicle model, the engine model and the SoftECU.
The following connection files can be added:
• BodyComponents_Basic-CU_EMS.xml
• CU_EMS-Vehicle.xml
• CU_Testbed-VehicleDynamics_Longitudinal.xml
• Driver_Longitudinal-CU_Testbed.xml
• Driver-CU_EMS.xml
• Driver-CU_TCU_MT.xml
• Drivetrain_Longitudinal-CU_EMS.xml
• Drivetrain_Longitudinal-CU_TCU_MT.xml
• Drivetrain_Longitudinal-CU_Testbed.xml
These above files are located in installation folder at
.\VVTB\Project Items\COSYM\VVTB_MT_ICE\conn
• CombustionEngine_G-VVTB_ICE.xml
• CombustionEngine-ICE_CU_EMS.xml

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• CU_EMS-ICE.xml
• VVTB-Init_p_Ambient-ICE.xml
• VVTB-Init_T_Ambient-ICE.xml
These files are located in installation folder at
.\ICE\Project Items\COSYM\ICE_G_1B_1Stg_DEMO\conn

To add connection files

1. Open the "Connections" view available at the bottom of the
opened "System".
2. Click on the "Import connections" icon.
3. Select each XML file mentioned above.
4. Click on "Import" to import connections from each file.
5. Repeat the steps 1 to 4 for all the connection files mentioned
above.
> After the connection files are added, the necessary connec-
tions are established between the VVTB, the engine model, and
the SoftECU. They are visible in the "Connections" view.

Fig. 5-1 COSYM Connections View for VVTB_ICE_LC

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Fig. 5-2 COSYM Diagram View with Connections VVTB_ICE_LC

NOTE
Check each connection file and ensure that you added all connection files.
Otherwise, the COSYM project might not work properly.

OS Configuration
Via the "Deployment" view, you can organize the processes of COSYM mod-
ules. For Simulink modules, the order of execution and the selection of a proper
step size is important. By default, tasks are not auto-generated for Simulink
modules when adding them to the project. Please click on + Auto mapping to
automatically map the processes to tasks. For added C-Code modules, ensure
that the timer processes under tasks are executed before the Simulink model
processes as shown in

Fig. 5-3 Execution of Timer Processes

NOTE
Both "Init" processes of C-Code modules must be assigned to the "Init" task.
This happens automatically when choosing the option + Auto mapping.

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In addition to the model tasks, it is important to generate a process hook. The

RT-Plugins require such process hooks.
To add RT-Plugins:
1. Right-click on TaskDVEModel.
2. Choose "Add Hook".
3. Name the hook Driver_RTPlugin.
4. Move this hook before the process
lcrt_OneStep_Outputs_VVTB.

> All relevant modules to operate the vehicle and the engine
model are available and you can build a COSYM project.
To build a COSYM project
1. Choose "Project" "Build and Run".
2. Click Build and Run.

For more details about the Simulink code generation, refer to the section “Sim-
ulink Model - Code Generation Process” on page 14.

5.1.2 Project Creation in LABCAR-OPERATOR

This section addresses qualified personnel with knowledge in using LABCAR-
OPERATOR. If you do not have any experience in using LABCAR-OPERATOR,
please read first [1].
For the manual project creation using LABCAR-MODEL-ICE with LABCAR-
OPERATOR follow the steps described in this section.

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To set up the LABCAR-OPERATOR project

1. Open the LABCAR-IP application.
2. Click File  New Project.
3. Choose the location for the file and name the project.
4. Use "RTPC" as "Target Name".
5. Click Finish.
> The project explorer contains an empty hardware configura-
tion.
The full vehicle model as well as the internal combustion engine model consist
each out of a single Simulink module. This module also contains driver, envi-
ronment, vehicle and SoftECU, which mimics the behavior of an EMS and will
control the internal combustion engine model.
To add the virtual vehicle testbench model
1. Choose Project  Add Module.
2. Select "Add Simulink (TM) Module".
3. Select "Use existing Simulink (TM) Model (will be copied)".
4. Select the full vehicle model configuration VVTB_MT_ICE. The
according model VVTB.mdl is located in the install folder
.\VVTB\Project Items\LCO\VVTB_MT_ICE\mdl\Sim
ulink_VVTB\src.
5. Click Finish.
> The Project Explorer shows the added module.
To add the internal combustion engine model
1. Choose Project  Add Module.
2. Select "Add Simulink (TM) Module".
3. Select "Use existing Simulink (TM) Model (will be copied)".
4. Select the internal combustion engine model configuration
ICE_G_1B_1Stg_DEMO. The according model
VVTB_ICE_LC.mdl is located in the install folder
.\ICE\Project Items\LCO\ICE_G_1B_1Stg_DEMO\
mdl\Simulink_VVTB_ICE_LC\src.
5. Activate the checkbox "Copy Model Directory into Project".
6. Click Finish.
> The Project Explorer shows the added model.
The internal combustion engine model requires initial environment conditions
for proper simulation. For this purpose, C-Code modules are used for tempera-
ture and pressure initialization.
To add a C-Code module
1. Choose Project  Add Module.
2. Select "Add C-Code Module".
3. Select "Use existing Module (will be copied)".

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4. Select the C-Code module within the internal combustion

engine model configuration ICE_G_1B_1Stg_DEMO for ambi-
ent pressure initialization. The according module
Init_p_Ambient.lmd is located in the install folder
.\ICE\Project Items\LCO\ICE_G_1B_1Stg_DEMO\
cmod\Init_p_Ambient.
5. Click Finish.
> The Project Explorer shows the added C-Code module.
To add the C-Code module for temperature initialization
1. Choose Project  Add Module.
2. Select "Add C-Code Module".
3. Select "Use existing Module (will be copied)".
4. Select the C-Code module within the internal combustion en-
gine model configuration ICE_G_1B_1Stg_DEMO for ambient
temperature initialization. The according module
Init_T_Ambient.lmd is located in the install folder
.\ICE\Project Items\LCO\ICE_G_1B_1Stg_DEMO\
cmod\Init_T_Ambient.
5. Click Finish.
6. The Project Explorer shows the added C-Code module.
Per default, no model connections are established. For example the SoftECU is
not connected to the vehicle, driver model or engine model, although it is part
of the already integrated Simulink module VVTB.mdl. Pre-defined connection
files couple the vehicle model, the engine model and the SoftECU.
To add connection files
1. Open "Connection Manager" and right-click.
2. Select Import Connection.
3. Import each connection file stored in the install folder at
.\VVTB\Project Items\LCO\VVTB_MT_ICE\conn
and at
.\ICE\Project Items\LCO\ICE_G_1B_1Stg_DEMO\
conn.

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> After the connection files are added, many connections are vis-
ible in the "Connection Manager".

NOTE
Check each connection file and ensure that you added all connection files.
Otherwise the model might not work properly.

OS Configuration
Via the "OS Configuration" tab, you can organize the processes of LABCAR-
OPERATOR modules. For Simulink modules, the order of execution and the
selection of a proper step size is of importance. Per default, proper tasks for the
Simulink model are auto-generated when adding the module to the project. For
added C-Code modules you have to assign the execute process manually.
First assign the two processes Init_p_Ambient_Execute and
Init_T_Ambient_Execute to the task TaskDVEModel.They are the first
two tasks of the execution order. Please ensure that both "Init" processes are
assigned to the "Init" task. In most cases this happens automatically.

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In addition to the model tasks, it is important to generate a process hook. The

RT-Plugins require such process hooks.
To add RT-Plugins
1. Generate a process hook for the task TaskDVEModel.
2. Name the hook Driver_RTPlugin.
3. Move this hook before the task
lcrt_OneStep_Outputs_VVTB.

> All relevant modules to operate the vehicle and the engine
model are available.
As a next step, you can build the LABCAR-OPERATOR project.

NOTE
Be sure to select the proper MATLAB version using the MATLAB Version
Selector. See [2].

To build a LABCAR-OPERATOR project

1. Choose Project Build.
2. Activate code generation for the "VVTB" module and the "VVT-
B_ICE_LC" module.

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3. Click Build.

The build process performs the following basic steps:

• Simulink code generation on the host PC
• Transfer of the source code to RTPC
• Compilation of sources on RTPC
• Transfer of binaries back to the host PC
For more details about Simulink Code Generation, see “Simulink Model - Code
Generation Process” on page 14.

5.1.3 Experiment Creation

After the successful build of the project in COSYM or LABCAR-OPERATOR, you
can prepare the experiment for the first execution of the simulation model.
Starting point is an empty experiment.

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Mapping Files
"Mapping files" provide a possibility to simplify the signal handling in LABCAR-
EE. For LABCAR-MODEL-VVTB various signal mappings are pre-defined. This
allows a simple access to most important simulation signals without in-depth
knowledge of the model.
1. Open Experiment Explorer
2. Add all mapping files located in the install folder at
.\VVTB\Project Items\LCO\VVTB_MT_ICE\
mapping.

NOTE
Ensure that the added mapping files are also activated.

Parameter Files
For LABCAR-MODEL-VVTB, no parameter files are provided. The default values
of the Simulink model are used.
For LABCAR-MODEL-ICE, a parameter file is provided to set the ambient envi-
ronment conditions.
• Open Experiment Explorer
• Add all cdfx files located in the install folder at
.\ICE\Project Items\LCO\ICE_G_1B_1Stg_DEMO\param\00
01_Initialization.

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NOTE
Ensure that the added parameter files are also activated.

RT-Plugin
RT-Plugins are compiled c-code snippets, which can be added to an experiment
without rebuilding the complete project. It is a tool to add user-defined function-
ality to an experiment. The GUI of the example project uses a RT-Plugin to
extend the functionality of the default instruments of LABCAR-EE.
To add RT-Plugins
1. Open Experiment Explorer
2. Add RT-Plugins located in the install folder at
.\VVTB\Project Items\LCO\VVTB_MT\rtp\
Driver_Instruments.

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> After the RT-Plugin is added, it is also available in the RT-Plugin

tab of LABCAR-EE. Open it to check its availability.
3. Open RT-Plugins tab.

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NOTE
Each RT-Plugin requires a process hook for execution. Ensure that the pro-
cess hook "Driver_RTPlugin" is available in the OS-settings. See the paragraph
“To add RT-Plugins” on page 35.

Layers
The "Layer" provides the basic interface to handle the vehicle model. It allows
the setting of the driver mode and the selection of pre-defined cycles. As a pre-
liminary step, you can copy images for the layer from the installation folder.
To import layers
1. Copy images from .\VVTB\Project Items\LCO\
VVTB_MT_ICE\img.
2. Create the target folder if it does not already exist in the Exper-
imentation folder and name it as "Image_Files".
3. Paste the images copied in step 1.
4. Import the Driver.layer file as located in .\VVTB\Project
Items\LCO\VVTB_MT_ICE\gui.

> After the successful import of the Driver layer, basic dash-
boards for handling the vehicle model exist.

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NOTE
All pre-defined instruments use mapped signals provided by the mapping
files. For proper execution, ensure that all mapping files are added to the
experiment.

NOTE
To extend the functionality of the standard instruments, so called RT-Plugins
are used. Ensure that the pre-compiled RT-Plugins are added to the experi-
ment.

NOTE
Consider that only default LABCAR-EE instruments are used. You can adapt
the layer individually to your needs.

All required artifacts for the first execution of the models are added to the
experiment. With that, the experiment is ready for the download to the RTPC
and the simulation. The section “Getting Started with the Tutorial Project” on
page 79 describes the handling of the simulation model in more detail.

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5.2 Getting Started with the Tutorial Project

The tutorial project for LABCAR-MODEL-ICE highlights two common aspects
when using LABCAR-MODEL-ICE in a project:
• Coupling of LABCAR-MODEL-ICE with a vehicle model
• Operation of LABCAR-MODEL-ICE without a physical engine control unit
Hence, following tutorial gives an introduction on how to use LABCAR-MODEL-
ICE in combination with a vehicle model. For that purpose, the detailed com-
bustion engine variant G_1B_1Stg is coupled with a manual transmission vehi-
cle model VVTB_MT_ICE. Please consider that the included vehicle model is
part of the LABCAR-MODEL-VVTB product. To run the tutorial project success-
fully, a license for LABCAR-MODEL-VVTB is required and needs to be pur-
chased separately. A physical control unit is not required, since the SoftECU of
LABCAR-MODEL-VVTB will be used to control the detailed combustion engine.
The tutorial project is located in
.\Example Projectt\LCO\05_VVTB_ICE.

NOTE
Please do not open or manipulate the example project in the installation
folder directly. Instead, copy the example project from the installation folder
to a location of your choice.

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5.2.1 Overview
By default, the experiment provides a single layer, which describes the driver of
the vehicle model. Since this comes originally with the LABCAR-MODEL-VVTB
product, see the section “User Interface” on page 52 for further information.
For the following tutorial tasks, please import an additional layer to the experi-
ment:
• Import the Throttle Manipulation layer file as located in the install folder
in .\Project Items\LCO\ICE_G_1B_1Stg_DEMO\gui.

The corresponding layer provides the interface to a few characteristics of the

engine model. It allows the setting of the simulation mode, the setting of the
cross sectional area of the throttle plate that directly affects the air mass flow
into the cylinder, and the visualization of the cross sectional area when the Soft-
ECU controls the engine.

Oscilloscopes
The layer is divided into visualization and editing fields. The three oscilloscopes
on the top of the layer show the air mass flow through the throttle, the pressure
in the intake manifold before the cylinder and the generated engine torque as a
main characteristic of an engine.

Parameters
The three fields at the bottom of the layer are used to switch between manual
mode and model mode during simulation. In this context, the model mode can
be considered as a closed loop operation, since the SoftECU replaces the func-
tionality of the throttle plate control of a real ECU.

5.2.2 Model Control Modes

As introduced, the LABCAR-MODEL-ICE provides two model control modes:

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Manual Mode
Many actuators and components provide parameters to switch and stimulate
inports or outports manually. This feature allows you to operate the component
in constant conditions. You can activate the mode and set a suitable value for
two parameters.

Model Mode
The same actuators and components as mentioned in the section "manual
mode" provide parameters to switch back to the model mode. Within this mode
the engine or, more precisely, the components will be controlled by an ECU and
will appear in dynamic conditions.

5.2.3 Manipulation of Air Mass Flow into Cylinder Through Throt-

tle Plate
The manual operation is the suitable starting point to close the different control
loops of a model. It is recommended to start with parametrization of stationary
behavior and move iteratively to transient behavior.
In this tutorial, the air mass flow will be directly manipulated via the cross sec-
tion area of the throttle plate. By increasing the cross section area, more air
mass will flow through. By decreasing the cross section area, less air is sup-
plied to the engine for combustion.

Constant Vehicle Speed

At first, after starting the simulation, the engine will be in idle operation. To see
modeled phenomena without any side effects, the vehicle will be manually
accelerated until it reaches a constant vehicle speed of 60 km/h.
To set the target speed, do the following
1. Switch to the drivers layer.
2. Set Cycle Off.
3. Chose Target Speed Manual.
4. Set the slider for vehicle speed target 60 km/h.

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Air Mass Flow Manipulation in Model Mode

The simulation is already started in the model mode. After the vehicle reaches
the desired constant velocity, switch back to the throttle manipulation layer.
The oscilloscopes show a constant air mass flow, intake pressure and engine
torque. As mentioned the throttle plate is controlled right from the start by the
SoftECU. The parameter field "Mass flow model" visualizes one throttle plate
opening in percent and the corresponding cross section if the SoftECU controls
the engine.
If the engine is in idle operation, the throttle plate is almost closed. The engine
has only to compensate the friction losses and no torque has to be generated.
This also leads to a small air mass flow that is required to operate in idle condi-
tion. After accelerating, the engine has to generate torque. The result is that
more air mass will be required for combustion and will be supplied by opening
the throttle plate.

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Air Mass Flow Manipulation in Manual Mode

To activate the manual mode
1. In the field "Simulation Control Parameters", set the parameter
Throttle__Area_Calc_DEVM_1_GEVM_0/Value 1
2. Set the parameter A_Throttle__Area_Mode Manual Mode
3. Set the parameter A_Throttle__Area_Manual 0.5
This setting allows you to directly enter the cross section area of the throttle
plate. Immediately after entering the air mass flow, the pressure and the engine
torque will reflect the chosen setting.

The following physical phenomena can be observed while manually manipulat-

ing the air mass flow:
By decreasing the cross section almost to zero, the throttle is closing. This
leads to an increased fluid resistance for the air, which wants to flow into the
cylinder. The engine power or/and the engine torque decreases significantly.
The drivers layer visualizes the described behavior.

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By increasing or decreasing, the relaxation of chambers can be observed. Look-

ing at the mass flow oscilloscope, a peak appears after entering. This peak
demonstrates the relaxation where the whole system is going to balance itself
after a disturbance.

5.3 Signal Interface

The basic interface to operate LABCAR-MODEL-ICE, as used in the section
“Getting Started with the Tutorial Project” on page 79, is listed in the following
table. LABCAR-MODEL-VVTB is used in combination with LABCAR-MODEL-
ICE. All required connections of VVTB and its components can be found within
the connections files of VVTB. Since LABCAR-MODEL-ICE is considered as an
add-on in the tutorial, the table contains all required connections to satisfy

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when running LABCAR-MODEL-ICE in combination with LABCAR-MODEL-

VVTB. If using LABCAR-MODEL-ICE with other drivetrain and driver models, the
required connections will differ.

NOTE
The table only contains a small excerpt from all available input and output
ports of the engine model. The model reference guide of LABCAR-MODEL-
ICE provides the complete documentation of the physical interfaces of each
S-Function and subsystem.

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5.3.1 Combustion Engine/Top Level

Inputs
Name Type Unit Description
phi_CAModel Double CA Crankshaft angle
FlywheelStandstill Bool - Engine operation status
Ignition Bool - Ignition status
p_Ambient Double Pa Ambient pressure
T_Ambient Double K Ambient temperature
Accelerator Double - Accelerator position
n_Engine Double rpm Engine speed
U_Batt Double V Battery voltage
M_Engage Double Nm Torque of auxiliary sys-
tems
v_Vehicle Double km/h Vehicle speed
v_Distance Double m Traveled distance of
vehicle
Clutch Double - Clutch pedal position
Gear Int - Gear position

Outputs
Name Type Unit Description
M_Engine Double Nm Engine torque
J_Engine Double kgm² Moment of inertia of
engine
M_EngineStick Double Nm Engine stick torque of
resting engine

5.3.2 Combustion Engine/Injection

Inputs
Name Type Unit Description
t_Injection1 Double µs Injection time cylinder 1
t_Injection2 Double µs Injection time cylinder 2
t_Injection3 Double µs Injection time cylinder 3
t_Injection4 Double µs Injection time cylinder 4
t_Injection5 Double µs Injection time cylinder 5
t_Injection6 Double µs Injection time cylinder 6

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5.3.3 Combustion Engine/Lambda Sensor

Inputs
Name Type Unit Description
Lambda Double - Lambda sensor before
catalyst

5.3.4 Combustion Engine/Throttle Plate

Inputs
Name Type Unit Description
ADC_Cannel_0_1 Double - Opening value throttle
plate

5.3.5 Combustion Engine/Engine Torque

Outputs
Name Type Unit Description
M_EngineOut_Nm Double Nm Effective drive torque
M_Ind_Nm Double Nm Indicated engine torque
M_Drag_Nm Double Nm Engine drag torque

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6 LABCAR-MODEL-PMSM
ETAS LABCAR-MODEL-PMSM is an FPGA-based simulation model of a 3-
phase permanent magnet synchronous e-motor (PMSM). The model includes
a model of an inverter, of the PMSM e-motor, and of a simple drivetrain.

6.1 Overview
As an FPGA-based simulation model, LABCAR-MODEL-PMSM requires the
ETAS ES5340.2-M FPGA board for execution [3]. LABCAR-MODEL-PMSM can
output signals directly via the analog output channels of the ES5340.2-M board.
The additional outputs of the slave board, ES5340.1-S, are currently unsup-
ported.
Two model variants are available: LABCAR-MODEL-PMSM Basic and LABCAR-
MODEL-PMSM Advanced. In addition to all the features of the Basic variant, the
Advanced variant offers a few more parameters, like iron losses in the e-motor
and Ohmic resistances in the inverter.
The model uses the ETAS FlexibleFPGA toolchain. Thus, many steps require
following the guidelines described in the FlexibleFPGA tutorial [4].

6.2 Project and Experiment Creation

This section lists all the necessary steps for setting up a small test project with
LABCAR-MODEL-PMSM using LABCAR-OPERATOR. It is divided into three sub-
sections that reflect the main steps: the procedure to flash LABCAR-MODEL-
PMSM to an ES5340.2-M board, the project creation in LABCAR-IP, and the
experiment creation in LABCAR-EE.
This section addresses qualified personnel with knowledge in using LABCAR-
OPERATOR. If unsure, please consider the documentation of LABCAR-OPERA-
TOR first [1]. When using ETAS COSYM, the steps in the second section differ
slightly. Please consider the COSYM User's Guide for details [3].

NOTE
Undefined behavior of the simulation model
There are two variants of this model: LABCAR-MODEL-PMSM Basic and
LACAR-MODEL-PMSM Advanced. Each variant has its own programming file
(*.euf) and its own interface description file (*.adf).
Mixing the programming file from one variant with the interface description
file from the other variant leads to undefined behavior.
Both files of a model variant (*.euf and *.adf) belong strictly to each other;
they cannot be mixed. Always use both files in combination when configuring
a project.

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6.2.1 Flashing Procedure

The prerequisite for using a LABCAR-OPERATOR project is flashing the model
to the ES5340.2-M. Ensure that the ES5340.2-M board is inserted to the RTPC
and the host PC is connected with the RTPC.
The following steps require the FlexFPGACopy tool, which is shipped together
with LABCAR-MODEL-PMSM as well as with FlexibleFPGA. It is available on the
product installation medium. Additionally, the steps require the ETAS HSP
Update tool. It is available either as part of LABCAR-OPERATOR or via down-
load on the ETAS Download Server.

NOTE
The HSP update tool is delivered with LABCAR-OPERATOR until version 5.4.7.
Newer versions of LABCAR-OPERATOR need a separate installation of the
HSP update tool. Please consider [2] to install the correct version of the HSP
update tool.

To program the LABCAR-MODEL-PMSM to the ES5340

NOTE
The HSP Update Tool flashes the model only if there is a valid
FlexibleFPGA license available. For installing the license refer to
[4].

1. Run "FlexFPGACopy.exe".
The tool copies the PMSM model file
("ES5340_2MFPGA67109121.euf") to the HSP installation
directory along with additional information. You find the two
files "FlexFPGACopy.exe" and ".euf" in the "FPGA Models"
folder of the LABCAR-MODEL-PMSM installation.
2. ClickCopy.

3. Start the HSP Update Tool and choose LABCAR-FWP service

package.
4. Use Functions Search for Hardware.

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5. Select ES5340M.
6. Select Licensed components.
The "Details" tab displays the licensed components of ES5340.
7. Select component FlexibleFPGA Support.

8. Use the Functions  Perform Update option of the HSP

Update Tool to flash/download the model.
> After the successful update, the below window appears.

9. Click OK.

The installed version (model version) of the "Component" "FlexibleFPGASup-

port" appears in the "Details" tab.

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6.2.2 Project Creation in LABCAR-OPERATOR

In the following, a step-by-step guide is given, which describes the generation
of a LABCAR-OPERATOR project using LABCAR-MODEL-PMSM. For the execu-
tion of the project, no physical ECU is needed. Instead, inverter switches can be
stimulated using failure model switch inputs. The resulting setup allows to exe-
cute the basic variant of LABCAR-MODEL-PMSM in a simple test environment.
For the manual project creation using LABCAR-MODEL-PMSM with LABCAR-
OPERATOR, follow the steps described in this section.
To set up the LABCAR-OPERATOR project
1. Open LABCAR-OPERATOR.
2. Create a new project called "PMSM_Basic".
> After creation, the LABCAR-OPERATOR project environment
looks as follows:

The LABCAR-MODEL-PMSM model is integrated into the LABCAR-OPERATOR

project using the hardware configuration.
To integrate the LABCAR-MODEL-PMSM model
1. In the Project Explorer, right-click on "Hardware" and select
Edit.

2. Right-click on "ES1130" and choose Delete Item.

3. Right-click on "RTPC::Rtpc" and choose
Add item ES5340-Hybrid.

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4. Click Ok.

5. Right click on "ES5340-Hybrid" and choose

Add Item ES5340-Master.
6. Click Ok.

7. Right-click on "ES5340-Master" and choose

Add Item ES5340-FlexibleFPGA.
8. Click Ok.
A window pops up.
9. Select PMSM_3Phase_dut.adf from
.\FPGA Models\PMSM_Basic in the installation directory.
> Now the LABCAR-MODEL-PMSM appears on LABCAR-RTC.

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NOTE
In the "Model ID" row, the string in parentheses is used for the internal track-
ing reference.

The "Globals" tab contains Model ID and Model Version.

The model version appears here in "hwc" and shall match with the model ver-
sion that is flashed by using the HSP tool as described in the section “Flashing
Procedure” on page 89.
The "Groups" tab contains the tasks for the interfaces to the model. As default,
it uses "TaskDVEModel".
The "Signals" tab contains the signal interface of the PMSM model.
The "Data" tab contains the values of input and output signals.

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In a further step, a Simulink module has to be integrated to the LABCAR-OPER-

ATOR project to download non-linear maps to the ES5340. The section “Nonlin-
ear Maps and Parameter Maps Downloader” on page 108 describes the
generation of current maps.
To integrate the RPM module
1. Right-click on "ES5340Master" and choose
Add item  ES5340-RPM.
2. Click Ok.

A new item is added in the hardware editor.

3. Set the parameters in the "Globals" tab according below figure.
The "Groups" tab contains the tasks for the interfaces to the
model. As default, it uses "TaskDVEModel".

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To integrate the Analog-Out-Mux

1. Right-click on "ES5340Master" and choose
Add item  ES5340-Analog-Out-Mux.
2. Click Ok.

A new item is added in the hardware editor.

The "Groups" tab contains the tasks for the interfaces to the
model. As default, it uses "TaskDVEModel".

You can set up to 8 channels for the Analog-Out-Mux.

3. For that, configure the according signals from Control_0 to
Control_7 in the "Signals" and "Data" tab as shown below.
In the example project, only 6 channels are used.

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Fig. 6-1 "Signals" Tab Analog-Out-Mux

Fig. 6-2 "Data" Tab Analog-Out-Mux

NOTE
Using the Sine encoder and resolver will bring the count of usable Analog Out-
puts to 6.

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To integrate the Simulink module

1. In the Project Explorer, select "RTPC" under "Targets".
2. Right-click and select Add Module.

3. Choose "Add Simulink (TM) Module" and click Next.

4. Select "Use existing Simulink (TM) Model (will be copied)" and
click Next.
5. Use browse to
.\Project Items\LCO\PMSM_Param_Download\mdl\
Simulink_PMSM_Map_Download\src in the install folder.
6. Choose "PMSM_Parameter_Maps_Download.mdl" to add the
Simulink module.
7. Click Finish.
> After successfully adding the Simulink module, the Project
Explorer will look like this:

The next step is to integrate a C-code module in order to be able to consider the
temperature effect of coils.
To add a C-Code module
1. In the Project Explorer, select "RTPC" under "Targets".
2. Right-click and select Add Module.

3. Choose "Add C-Code Module" and click Next.

4. Select "Use existing C-Code Module (will be copied)" and click
Next.

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5. Click Browse and go to

.\Project Items\LCO\PMSM_T2R_Coil\cmod\PMSM_T
2R_Coil in the install folder.
6. Choose PMSM_T2R_Coil.lmd to add the C-Code module.
7. Click Finish.
> After successfully adding the C-Code module, the Project
Explorer will look like this.

Connection Manager
Per default, the Simulink module and the C-Code module are not connected to
the FPGA model. Hence, connection files are used to connect the Simulink
module and the C-Code module with the FPGA model.
To connect the modules
1. Go to the "Connection Manager" tab in the LABCAR-OPERA-
TOR project.

2. Click Update Ports in case the interfaces for "Hardware" do not

appear in the "Connection Manager" tab.
3. Right click on the "Existing Connections" window and click
Import Connections.
4. Click Browse and go to
.\Project Items\LCO\PMSM_Param_Download\conn
in the install folder.

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5. Import the connection file

"PMSM_Parameter_Maps_Download_FPGA.xml" to
establish the connections between PMSM Model and the
module.
6. Click Browse and go to
.\Project Items\LCO\PMSM_T2R_Coil\conn in the
install folder and import the connection file
PMSM_T2R_Coil_FPGA.xml.
> After the import of all connections the "Connection Manager"
tab will look as follows:

OS Configuration
Using the "OS configuration", you can organize the processes of LABCAR-
OPERATOR modules. For the added Simulink module and C-Code module, the
order of execution and the selection of a proper step size is important.
To configure the OS Configuration
1. Go to the "OS Configuration" tab.
2. Click Update Processes.
3. Remove unused processes (in gray).

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4. Right-click in the task window and choose Add Task and

rename it to
"TaskDVEModel_Parameter_Download".

5. Unselect the "Outputs" and "States" of "PMSM_Parameter_-

Maps_Download" from the "TaskDVEModel" task and assign
to "TaskDVEModel_Parameter_Download".

6. In the "Task" window, select "TaskDVMModel".

7. Set the period to 0.0001.

8. In the "Task" window, select "TaskDVEModel_Parame-

ter_Download".
9. Set the period to 0.0004 s.
10.Click Save All.

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The basic modules to operate the LABACR-MODEL-PMSM basic model are

added to the project. In the next step, you can build the LABCAR-OPERATOR
project.
To build a LABCAR-OPERATOR project
1. Connect the RTPC.
2. Select Project  Build with option "All".
3. Click Build.

6.2.3 Experiment Creation

After the successful build of the project, you can prepare the experiment for the
first execution of the simulation model. Ensure that the model version flashed
as described in section “Flashing Procedure” on page 89 is the same as the
model version that is used in the section “Project Creation in LABCAR-OPERA-
TOR” on page 91.
To start LABCAR-EE and to access the LABCAR-MODEL-PMSM ports
1. Open LABCAR-EE using LABCAR-IP
ToolsOpen Experiment Environment

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> LACBCAR-EE opens.

2. Select Experiment Download LABCAR.

3. In “WorkSpaceElements” right-click on LABCAR RTPC.
4. Click Show All HW Ports.

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> All the ports to the PMSM model are visible.

Parameter Files
No parameter files are provided. The default values of LABCAR-MODEL-PMSM
are used.

Layers
The layer provides the basic interface to handle the PMSM model. It allows the
setting of the driver mode and the selection of predefined cycles.

NOTE
Please consider that only default LABCAR-EE instruments are used. The layer
can be adapted individually to your needs.

The following layers must be installed.

• PMSM_Simulation_Control.layer
• PMSM_Failure_Simulations.layer
• PMSM_Parameters_Basic.layer or PMSM_Parameters_Ad-
vanced.layer
• PMSM_DAC.layer
• PMSM_Runtime_License.layer
You find the layers in the install folder under
• PMSM_common\gui
• 02_PMSM_Advanced_specific\gui
• 03_PMSM_Basic_specific\gui

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To add layers
1. Right click on Instrumentation Layer.
2. Click Import Layer to add layers.

NOTE
All pre-defined instruments use mapped signals provided by the mapping
files. For proper execution, ensure that all mapping files are added to the
experiment.

> After adding all mapping files, layers, and images, the experi-
mental environment will look like below:

All required artifacts for the first execution of the PMSM_Basic model are
added to the experiment. With that, the project can be downloaded to the RTPC.
The simulation can be started with the prerequisite of flashing the PMSM
model as described in section “Flashing Procedure” on page 89. The section
“Getting Started with Tutorial Project” on page 105 describes the handling of
the simulation model in more detail.

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6.3 Getting Started with Tutorial Project

The following tutorial gives an introduction on how to use LABCAR-MODEL-
PMSM. The project includes a hardware configuration for a PMSM model run-
ning on a ES5340.2-M as well as an example parameter set. To run the model
successfully, it is mandatory to flash the ES5340.2-M beforehand with the pro-
vided programming files. For further information, see “Flashing Procedure” on
page 89.
The tutorial project is located in
.\Example Project\LCO\03_PMSM_Basic in the install folder.

NOTE
Please do not open or manipulate the example project in the installation
folder directly. Instead, copy the example project from the installation folder
to a location of your choice.

6.3.1 Active Short-Circuit Operation Mode

In this example project, LABCAR-MODEL-PMSM is operated under active short
condition. This test operating mode does not require any PWM signal actuation
to the model. The e-motor is rotated using the speed mode of the drivetrain.
The inverter IGBT switches are stimulated using "Fail_IGBT" input of the mode.
The following section describes details to run the model in a simple test envi-
ronment.

NOTE
Ensure that the PMSM license keys are given in the "PMSM Runtime License"
layer and that the status is green or the "Lic_Out" signal is at 1.

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1. Connect the relay.

For example: The battery is connected with the inverter.
Use the "PMSM Simulation Control" GUI Layer for setting this
input.

The intermediate circuit flag can be set to "Disconnected" in

"PMSM Parameters" layer. Thus the DC bus voltage is the
same as the battery voltage.
2. Use "PMSM Parameters" layer to set the linear mode of the
model.
The input Ld and Lq values are used to compute the Id and Iq
values.
3. Set sample test parameters as shown below.

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4. Use the "PMSM Failure Simulations" layer to set the gate signal
input to the switches. Use all the high side switches to stuck to
low and the low side switches to stuck to high.
This essentially simulates an active short circuit.

5. Use the Speed Input of the Drivetrain to achieve a positive

speed.

In the image above you see that the currents flow in the motor
and the breaking torque is generated i.e., a negative torque is
generated.

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6.4 Nonlinear Maps and Parameter Maps Downloader

The saturation of the machine core is considered using maps of inductance as
a function of currents i.e., Ld and Lq as f ( Id , Iq ). LABCAR-MODEL uses an entire-
flux model for simulating saturation effects, so that an inversion of the induc-
tance maps is required. Hence, the current maps as functions of fluxes
Id (  d,  q) and Iq (  d,  q) are required.
Here
Ld and Lq are inductance [H] along d and q axis respectively.
Id and Iq are currents [A] along d and q axis respectively.
d and q are fluxes [Vs] along d and q axis respectively.
The section consists of two parts. The first part is a MATLAB based tool to
invert the inductance data maps to obtain the current data maps. The second
part is a Simulink module to download the current data maps to the ES5340.2-
M.

A MATLAB based tool "CurrentTablesGenerationTool.m" is provided to

invert the inductance tables ( f( Id , Iq ) ) to obtain lookup tables for Id and Iq
(f( d and q)). The tool "CurrentTablesGenerationTool.m" is located at
.\FPGA Model\PMSM_Param_Download\EMachineData_PreProcess
ing.
You can provide the inductance lookup table data (shall not contain any com-
plex numbers) Ld and Lq with row break points of Id and column break points of
Iq to a dedicated file "EngineInputData.m". The lookup tables are written to
"GeneratedTables.txt". The data can be further used with a Simulink mod-
ule to download to FPGA.
The tool has the following important characteristics.
• Equidistant and identical breakpoints in d-direction ( d) and q-direction
( q) of lookup tables.
• The distance of breakpoints is a power of two for powerful FPGA usage.
• No extrapolation i.e. means that at the end point the map is clipped.
• Bilinear interpolation with possibility of different interpolation methods.
• The lookup tables data is provided for positive and negative axis for (d)
for simulation performance reasons.

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• The maximum size of each lookup table is the number of rows multiplied
with the number of currents. It is more or less equal to 52200 (Maximum
number of data points allowed on the FPGA RAM).
A Simulink module "PMSM_Parameter_Maps_Download" is provided to down-
load the current maps to the ES5340.2-M. The connection file
"PMSM_Parameter_Maps_Download_FPGA.xml" consists of the connec-
tion between the Simulink module and the FPGA model. The Simulink module
needs to be added to the project and the connections need to be imported. The
section “Project and Experiment Creation” on page 88 describes how to add the
Simulink module and how to import the connections.
The Simulink module consists of a file "PMSM_Parameter_Maps.m" to pro-
vide current maps of Id and Iq and the break points vectors d and q.
The current maps and break points needs to be obtained from the
"CurrentTablesGenerationTool.m" discussed above.
"GeneratedTables.txt" consists of the current maps data and break points
data. This data needs to be entered to "PMSM_Parameter_Maps.m". By set-
ting the Simulink module input "RAM_Write_Trigger" to 1, the writing of data
fields to the FPGA is enabled. When writing the data fields to the ES5340.2-M
board, the FPGA model input "Reset" is set to 1.
Use the "Linear_NonLinear_Selector" input of the FPGA model to use the
non-linear mode of the simulation.

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6.5 Signal Interface

In the following, the basic interfaces to operate LABCAR-MODEL-PMSM are
given.

6.5.1 Drivetrain Interfaces

Inputs
Name Type Unit Description
T_L Fixdt(1,32,21) Nm Load torque
Phi_mech_Init Fixdt(0,32,28) rad Initial mechanical rotor
angle
Omega_Input Fixdt(1,32,15) rad/s Speed input of drivetrain
in speed mode

Outputs
Name Type Unit Description DAC Multiplexer
Input Number
Omega_mech Fixdt(1,32,15) rad/s Mechanical rotor speed 1
Omega_el Fixdt(1,32,15) rad/s Electrical rotor speed 0
Phi_mech_rad Fixdt(0,18,15) rad Mechanical rotor angle 3
Phi_el Fixdt(1,18,15) rad Electrical rotor angle 2
T_mech Fixdt(1,32,21) Nm Resulting mechanical rotor 4
torque
Tel_average Fixdt(1,32,18) Nm Average electrical torque 5
n_load_rpm Int32 rpm Mechanical load speed 27
n_rotor_rpm Int32 rpm Mechanical rotor speed -
phi_rotor_deg Uint16 degree Mechanical rotor angle -

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Parameters
Name Type Unit Description Default Range
f Fixdt(0,32,28) Nms/ Friction coefficient of E-machine; 0.1 0.0...10
rad to deactivate set parameter to
zero value
C Fixdt(0,32,8) Nm/ Torsional stiffness between rotor 1500000 0.0...100
rad and load; to deactivate set param- 00000
eter to zero value
D Fixdt(0,32,22) Nms/ Damping between rotor and load; 100.0 0.0...100
rad to deactivate set parameter to
zero value
Direct Boolean - mode selector 0 [0,1]
Feed 0: use torque input
through 1: use speed input
invJ_E Fixdt(0,32,12) 1/ Inverse of inertia of rotor 10 0.1...1e5
kgm2
invJ_L Fixdt(0,32,12) 1/ Inverse of inertia of load/drive- 10 0.1...1e5
kgm2 train

6.5.2 Inverter Interfaces

Inputs
Name Type Unit Description
PWM_UH Boolean - Control signal upper IGBT phase U
PWM_UL Boolean - Control signal lower IGBT phase U
PWM_VH Boolean - Control signal upper IGBT phase V
PWM_VL Boolean - Control signal lower IGBT phase V
PWM_WH Boolean - Control signal upper IGBT phase W
PWM_WL Boolean - Control signal lower IGBT phase W
Gate_Signal_Polarity Boolean - IGBT Polarity Control
0: Low active, conducting while gate is
"Low"
1: High active, conducting while gate is
"High"
Fail_IGBT_HS_U Fixdt(0,2,0) - Gate failure mode of high side switch of
phase U
0: Normal Operation
1: Stuck on "Low"
2: Stuck on "High"
Fail_IGBT_HL_U Fixdt(0,2,0) - Gate failure mode of low side switch of
phase U
0: Normal Operation
1: Stuck on "Low"
2: Stuck on "High"
Fail_IGBT_HS_V Fixdt(0,2,0) - Gate failure mode of low side switch of
phase V
0: Normal Operation
1: Stuck on "Low"
2: Stuck on "High"

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Name Type Unit Description

Fail_IGBT_HL_V Fixdt(0,2,0) - Gate failure mode of high side switch of
phase V
0: Normal Operation
1: Stuck on "Low"
2: Stuck on "High"
Fail_IGBT_HS_W Fixdt(0,2,0) - Gate failure mode of high side switch of
phase W
0: Normal Operation
1: Stuck on "Low"
2: Stuck on "High"
Fail_IGBT_HL_W Fixdt(0,2,0) - Gate failure mode of low side switch of
phase W
0: Normal Operation
1: Stuck on "Low"
2: Stuck on "High"
Fail_Diode_HS_U Fixdt(0,2,0) - Diode failure mode of high side switch
of phase U
0: Normal Operation
1: Stuck on "Low"
2: Stuck on "High"
Fail_Diode_HL_U Fixdt(0,2,0) - Diode failure mode of low side switch
of phase U
0: Normal Operation
1: Stuck on "Low"
2: Stuck on "High"
Fail_Diode_HS_V Fixdt(0,2,0) - Diode failure mode of high side switch
of phase V
0: Normal Operation
1: Stuck on "Low"
2: Stuck on "High"
Fail_Diode_HL_V Fixdt(0,2,0) - Diode failure mode of low side switch
of phase V
0: Normal Operation
1: Stuck on "Low"
2: Stuck on "High"
Fail_Diode_HS_W Fixdt(0,2,0) - Diode failure mode of high side switch
of phase W
0: Normal Operation
1: Stuck on "Low"
2: Stuck on "High"
Fail_Diode_HL_W Fixdt(0,2,0) - Diode failure mode of low side switch
of phase W
0: Normal Operation
1: Stuck on "Low"
2: Stuck on "High"
U_Batt0 Fixdt(0,16,5) V Input voltage of battery

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Name Type Unit Description

RC_Ckt_Disable_Flag Boolean - Intermediate circuit disable flag
0: Intermediate circuit enabled
1: Intermediate circuit disabled
Relay_Switch Boolean - Switch to connect/disconnect battery
0: Battery disconnected
1: Battery connected

ShortCircuit_Flag_Reset Boolean - Input for resetting short circuit error

flags

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Outputs
Name Type Unit Description DAC Multiplexer
Input Number
U_DC Fixdt(1,32,18) V Intermediate circuit voltage 19
I_Bat Fixdt(1,32,18) A Battery current -
I_DC Fixdt(1,18,4) A Intermediate circuit current 20
U_phase_U Fixdt(1,32,18) V Voltage phase U 9
U_phase_V Fixdt(1,32,18) V Voltage phase V 10
U_phase_W Fixdt(1,32,18) V Voltage phase W 11
ShortCircuit_Error_- Boolean - Short circuit error flag for half -
Flag_U bridge phase U
ShortCircuit_Error_- Boolean - Short circuit error flag for half -
Flag_V bridge phase V
ShortCircuit_Error_- Boolean - Short circuit error flag for half -
Flag_W bridge Phase W
I_element_H_U Fixdt(1,16,4) A Current through upper switch -
phase U
I_element_H_V Fixdt(1,16,4) A Current through upper switch -
phase V
I_element_H_W Fixdt(1,16,4) A Current through upper switch -
phase W
I_element_L_U Fixdt(1,16,4) A Current through lower switch -
phase U
I_element_L_V Fixdt(1,16,4) A Current through lower switch -
phase V
I_element_L_W Fixdt(1,16,4) A Current through lower switch -
phase W
U_Switch_H_U Fixdt(1,32,18) V Voltage on upper switch -
phase U
U_Switch_H_V Fixdt(1,32,18) V Voltage on upper switch -
phase V
U_Switch_H_W Fixdt(1,32,18) V Voltage on upper switch -
phase W
U_Switch_L_U Fixdt(1,32,18) V Voltage on lower switch -
phase U
U_Switch_L_V Fixdt(1,32,18) V Voltage on lower switch -
phase V
U_Switch_L_W Fixdt(1,32,18) V Voltage on lower switch -
phase W
Blocked_U Boolean - Flag set if both upper and -
lower switches of phase U are
open
Blocked_V Boolean - Flag set if both upper and -
lower switches of phase V are
open
Blocked_W Boolean - Flag set if both upper and -
lower switches of phase W are
open

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Parameters
Name Type Unit Description Default Range
U_D_Fwd Fixdt(0,16,14) V Conducting volt- 0.2 0.01...3
age in diode
(293.15K)
Inv_R_Batt Fixdt(0,16,12) 1/  Inverse of inner 0.5 1e-3...10
resistance of bat-
tery
Inv_C_DC Fixdt(0,16,12) 1/  F Inverse of inter- 0.1 1e-3...0.1
mediate circuit
capacitor
T_Switch 1 Fixdt(0,16,32) s Switching time of 5e-6 0.2e-6
IGBT ...10e -6
R_SW_ON 1 Fixdt(0,16,20)  Conducting resis- 0.001 0.0...0.05
tance in IGBT
R_D_FWD 1 Fixdt(0,16,20)  Conducting resis- 0.001 0.0...0.05
tance in diode
U_SW_Fwd 1 Fixdt(0,16,14) V Conducting volt- 0.2 0.01...3
age in
IGBT(293.15K)

1
This signal is only available in LABCAR-MODEL-PMSM Advanced.

NOTE
The time constant of the intermediate circuit (R_Batt * C_DC ) must be
greater than 1 s.

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6.5.3 PMSM Motor Interfaces

Inputs
Name Type Unit Description
Rs Single  Stator coil resistance
2
Riron Single  Resistance represents iron
losses of machine
L_d Single H Inductance in d-axis
L_q Single H Inductance in q-axis
Psi_Rotor Single Wb (Vs) Permanent magnetic flux in
rotor
Linear_NonLinear_Selector Boolean - 0: linear mode, inputs "L_d"
and "L_q" are used.
1: Nonlinear mode, nonlinear
maps Id(Psi_d, Psi_q) and
lq(Psi_d, Psi _q) are used.
Current_DQ_Selector Boolean - 0: Internally calculated values
for I_d and I_q are used.
1: Stimulus inputs "ID_Stimu-
late" and "IQ_Stimulate" are
used.
ID_Stimulate Single A Stimulating input for I_d
IQ_Stimulate Single A Stimulating input for I_q
Reset Boolean - Reset all internal states
AngleCorrectionSamples Fixdt(0,8,2) - Number of samples consid-
ered for angle correction of I_d
and I_q calculations
RAM_Write_Prog Boolean - Indication if data is written to
FPGA RAM
ram_select_Id Uint16 - Selector to write data into the
d-axis RAM block
ram_adr_Id Uint32 - RAM address to write in d-axis
RAM block
ram_din_Id Int32 - Data for d-axis
ram_select_Iq Uint16 - Selector to write data into the
q-axis RAM block
ram_adr_Iq Uint32 - RAM address to write in q-axis
RAM block
ram_din_Iq Int32 - Data for q-axis
X1min_Psid Fixdt(1,36,26) Wb (Vs) Minimum break point in d-axis
direction
X2min_Psiq Fixdt(1,36,26) Wb (Vs) Minimum break point in q-axis
direction
discr1_Psid Int8 - Distance between break
points in d-axis direction
discr2_Psiq Int8 - Distance between break
points in q-axis direction

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Name Type Unit Description

N1_Psi_d Uint16 - Number of break points in d-
axis direction
N2_Psi_q Uint16 - Number of break points in q-
axis direction
X1max_Psi_d Fixdt(1,36,26) Wb (Vs) Maximum break point in d-axis
direction
X2max_Psi_q Fixdt(1,36,26) Wb (Vs) Maximum break point in q-axis
direction

2
This signal is only available in LABCAR-MODEL-PMSM Advanced.

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Outputs
Name Type Unit Description DAC Multiplexer
Input Number
Vd Single V Voltage in d-axis -
Vq Single V Voltage in q-axis -
Psi_d Single Wb Flux in d-axis 17
(Vs)
Psi_q Single Wb Flux in q-axis 18
(Vs)
Torque Single Nm Motor electromagnetic -
torque
U_Ind_U Single V Induced back EMF of 14
phase U
U_ind_V Single V Induced back EMF of 15
phase V
U_ind_W Single V Induced back EMF of 16
phase W
I_Phase_U Single A Current of phase U 6
I_Phase_V Single A Current of phase V 7
I_Phase_W Single A Current of phase W 8
ld Single A Current in d-axis 12
lq Single A Current in q-axis 13
PLoss_Copper Single W Copper loss of motor 25
PLoss_Core Single W Core loss of motor 26
Icd Single A Current in core loss 21
branch of d-axis
Icq Single A Current in core loss 22
branch q-axis
Imd Single A Current in magnetization 23
branch of d-axis
Imq Single A Current in magnetization 24
branch of q-axis

Parameters
Name Type Unit Description Default Range
PPN Uint8 - Number of pole 1 1...32
pairs

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6.5.4 License Keys Interface

Inputs
Name Type Unit Description
Lic_0 Uint32 - License key
number 0
Lic_1 Uint32 - License key
number 1
Lic_2 Uint32 - License key
number 2
Lic_3 Uint32 - License key
number 3
Lic_4 Uint32 - License key
number 4

Output
Name Type Unit Description DAC Multiplexer
Input Number
Lic_Out Boolean - Indication if license keys are -
correct

6.5.5 Analog Outputs

The LABCAR-MODEL-PMSM supports the 8 analog outputs of the ES5340.2-M
board.

NOTE
The resolver sensor, which is also implemented in the FPGA on the
ES5340.2-M, uses the analog outputs #6 and #7. When it is intended to use a
resolver sensor, the analog outputs #6 and #7 are unavailable to the FPGA
model.

Each electrical output channel of the ES5340.2-M can be connected to any

other signal of the simulation model by using the multiplexer as described in
the column "DAC Multiplexer Input Number". By choosing the multiplexer input
number, a particular model signal can be connected to the analog output chan-
nel. Each output channel can be configured further on by parameters, which
can influence the output voltage of the board that are represented in the table
below.
Additionally the following demonstration provides an overview about the inter-
faces and the selectable signals of LABCAR-MODEL-PMSM.

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Fig. 6-3 LABCAR-MODEL-PMSM Model Interface Overview

Name Type Unit Description

ScalingFactor_AnaOut_0 Fixdt(1,20,17) - Scaling factor for scaling output to
10 V of analog channel 0
ScalingFactor_AnaOut_1 Fixdt(1,20,17) - Scaling factor for scaling output to
10 V of analog channel 1
ScalingFactor_AnaOut_2 Fixdt(1,20,17) - Scaling factor for scaling output to
10 V of analog channel 2
ScalingFactor_AnaOut_3 Fixdt(1,20,17) - Scaling factor for scaling output to
10 V of analog channel 3
ScalingFactor_AnaOut_4 Fixdt(1,20,17) - Scaling factor for scaling output to
10 V of analog channel 4
ScalingFactor_AnaOut_5 Fixdt(1,20,17) - Scaling factor for scaling output to
10 V of analog channel 5
ScalingFactor_AnaOut_6 Fixdt(1,20,17) - Scaling factor for scaling output to
10 V of analog channel 6
ScalingFactor_AnaOut_7 Fixdt(1,20,17) - Scaling factor for scaling output to
10 V of analog channel 7
Offset_AnaOut_0 Fixdt(1,16,11) V Offset for setting voltage level of
analog output channel 0
Offset_AnaOut_1 Fixdt(1,16,11) V Offset for setting voltage level of
analog output channel 1
Offset_AnaOut_2 Fixdt(1,16,11) V Offset for setting voltage level of
analog output channel 2
Offset_AnaOut_3 Fixdt(1,16,11) V Offset for setting voltage level of
analog output channel 3
Offset_AnaOut_4 Fixdt(1,16,11) V Offset for setting voltage level of
analog output channel 4
Offset_AnaOut_5 Fixdt(1,16,11) V Offset for setting voltage level of
analog output channel 5
Offset_AnaOut_6 Fixdt(1,16,11) V Offset for setting voltage level of
analog output channel 6
Offset_AnaOut_7 Fixdt(1,16,11) V Offset for setting voltage level of
analog output channel 7

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Name Type Unit Description

Max_AnaOut_0 Fixdt(1,16,11) V For setting maximum output volt-
age level of board of channel 0
Max_AnaOut_1 Fixdt(1,16,11) V For setting maximum output volt-
age level of board of channel 1
Max_AnaOut_2 Fixdt(1,16,11) V For setting maximum output volt-
age level of board of channel 2
Max_AnaOut_3 Fixdt(1,16,11) V For setting maximum output volt-
age level of board of channel 3
Max_AnaOut_4 Fixdt(1,16,11) V For setting maximum output volt-
age level of board of channel 4
Max_AnaOut_5 Fixdt(1,16,11) V For setting maximum output volt-
age level of board of channel 5
Max_AnaOut_6 Fixdt(1,16,11) V For setting maximum output volt-
age level of board of channel 6
Max_AnaOut_7 Fixdt(1,16,11) V For setting maximum output volt-
age level of board of channel 7
Min_AnaOut_0 Fixdt(1,16,11) V For setting minimum output volt-
age level of board of channel 0
Min_AnaOut_1 Fixdt(1,16,11) V For setting minimum output volt-
age level of board of channel 1
Min_AnaOut_2 Fixdt(1,16,11) V For setting minimum output volt-
age level of board of channel 2
Min_AnaOut_3 Fixdt(1,16,11) V For setting minimum output volt-
age level of board of channel 3
Min_AnaOut_4 Fixdt(1,16,11) V For setting minimum output volt-
age level of board of channel 4
Min_AnaOut_5 Fixdt(1,16,11) V For setting minimum output volt-
age level of board of channel 5
Min_AnaOut_6 Fixdt(1,16,11) V For setting minimum output volt-
age level of board of channel 6
Min_AnaOut_7 Fixdt(1,16,11) V For setting minimum output volt-
age level of board of channel 7

6.5.6 Digital Inputs

LABCAR-MODEL-PMSM requires 6 digital PWM input signals for controlling the
IGBTs of the inverter. These signals need to be added to the project using in the
Hardware Configuration. Please see the LABCAR-OPERATOR manual for
details [1].
The "Digital Input of hardware" channel can be connected to LABCAR-MODEL-
PMSM using "hwc" as shown below.

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6.6 User Interfaces

A GUI for LABCAR-EE is included with LABCAR-MODEL-PMSM. It allows to
operate the model conveniently and contains layers for selecting various
modes of operation, for entering the license key, and for obtaining the model
status.
The following layers are available:
• PMSM Runtime License
• PMSM Simulation Control
• PMSM DAC
• PMSM Failure Simulations
• PMSM Parameters

6.6.1 PMSM Runtime License

This GUI provides an interface to enter license keys and to obtain the license
status. The license keys are provided in hexadecimal notation.
The two model variants LABCAR-MODEL-PMSM Basic and LABCAR-MODEL-
PMSM Advanced require different license keys. As a result, the signals "License
Key 0-4" to be entered there are different.

If you enter correct license keys/codes the "license status" will be green, other-
wise it will remain gray.

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Entering the license keys manually to your project after every restart is a
tedious task. For eliminating this effort, you may export the license keys as a
partial parametrization of your project. LABCAR-EE offers a functionality to
save and to load such a partial parametrization automatically after restart. It is
described in detail in section 4.6.4 of the LABCAR-OPERATOR User's Guide [1].
Briefly, the steps for achieving an automatic loading of this partial parametriza-
tion are as follows.
To export the license keys as a partial parametrization
1. Download the experiment to your RTPC.
2. Enter the 5 license keys in LABCAR-EE.
3. Expand the HW ports with a right mouse button click in "Work-
space Elements" and select "Show All HW Ports".
4. Navigate in the "Workspace Elements" to the previously
entered license keys, i.e. to the labels mentioned below:

5. Select all 5 signals in the "Workspace elements".

6. Right click on the selected signals and select Signal  Save
Input Signal Settings....
7. Create a parameter file by selecting a file name.

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8. Activate the "Add To Experiment" check box.

9. Activate the "Activate File" check box.
10.Select "Save".

6.6.2 PMSM Simulation Control

This is a GUI layer for the simulation control of LABCAR-MODEL-PMSM. The
important interfaces for drivetrain, inverter and motor can be controlled using
this layer.

• "Drivetrain" Section of GUI

Here you can enter the mechanical "Speed Input" (speed mode) and the
"Load Torque" (torque mode).
• "Inverter" Section of GUI
Here you enter the "Gate Polarity" of input PWM signals, the relay con-
nection of the inverter with the battery, and the battery voltage.
• "PMSM" Section of GUI
Here you enter the model reset and mode selector (model internal val-
ues/stimulation) with ID and IQ Stimulus input values.

NOTE
Use the mode selector to tune the resolver and DAC interfaces of the HiL
setup.

NOTE
The currents shown in the oscilloscope of the GUI have the unit [A], and the
voltages have the unit [V].

6.6.3 PMSM DAC

As described in section “Signal Interface” on page 110, internal signals can be
used with an analog output channel using a multiplexer. This GUI provides an
easy interface to select signals and to input the scaling factor and minimum
and maximum voltage values on the analog output channel.

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Each analog output can be connected to one value of the simulation model.
You can decide which signal is displayed, how this signal is scaled on the ±10 V
output, if there is an offset to this signal, and what the maximum and minimum
output voltages are (limited to ±10 V).

For each signal used on the analog output channel, you can define a scaling
factor using the parameter. The desired scaling factor can be computed by the
following equation:
ScalingFactor = DesiredVoltageLevel / SignalValue
For example: To represent the model signal value of 200 A as an output voltage
value of 10 V at the analog output of the ES5340.2-M, the scaling factor must
be set to 10 V divided by 200 A = 0.05 V/A.

NOTE
To set the Offset to the signal voltage, use the model parameter
"Offset_Anaout_X(X=0…6)".

6.6.4 PMSM Failure Simulations

This GUI layer provides an interface to insert various fault (stuck on "high" or
stuck on "low") states to IGBT and diode. The short circuit indication flag on
each phase is provided. A reset is provided to clear the short circuit flag.

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• IGBT and Diode failure simulations

For each switch/diode three states are possible.

– No Error:
This is a normal working state of the switch/diode i.e. the input PWM
signal is considered.
– Stuck to High:
The switch is stuck to high potential.
– Stuck to Low:
The switch is stuck to low potential.
• Short circuit indicator
For each phase of the inverter, a flag indicates if a short occurs i.e. LED
turns red if there is a short-circuit.

The "Reset" input can be used to clear the short-circuit indication flags of
all phases.

6.6.5 PMSM Parameters

This layer consists of an interface to scalar parameters of the drivetrain, the
inverter, and the PMSM motor.
The interfaces of the subsystems, e.g. drivetrain, inverter, and PMSM motor,
are documented in detail in the section “Signal Interface” on page 110.

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The GUI uses standard instruments. This can easily be used as a template for
individual GUIs.

6.6.6 PMSM Drivetrain

The GUI provides information about the drivetrain including the output of the
hardware item ES5340-RPM.

The GUI shows the following 5 sections:

A Torque or speed stimulation settings of drivetrain
B Model rotor speed information - n_rotor_rpm
C E-Machine torque information - mechanical as well as electrical

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D Rotor angle information of the model and ES5340-RPM hardware item -

phi_rotor_deg, ActMechAngle
E Model load torque information - load torque only

6.7 Migration from PMSM Model for ES5340 V1.0

Before the LABCAR-MODEL-PMSM V4.1.1 release, a former version existed
with name FPGA Inverter/PMSM Model for ES5340 V1.0. Functionality and
naming conventions changed from that version. This section serves as an
entry point to users with the intent to migrate their project from the older model
to the current LABCAR-MODEL-PMSM V4.x. It refers to the appropriate sec-
tions within this User's Guide and highlights differences between the V1.0 and
V4.x.
If an existing project with the old version V1.0 shall be migrated to LABCAR-
MODEL-PMSM V4.x, several measures have to be taken.
The following subsections provide you with hints and references for a success-
ful migration of your old project.

6.7.1 FlexibleFPGA License

The LABCAR-MODEL-PMSM needs a FlexibleFPGA license tag, which is
included in every delivery. The flashing of the FPGA, as described in the next
section, can only take place, if this license has been installed into your ES5340
board. For installing such a license refer to "FlexibleFPGA V3.0.0 - Workflow
Description: Tutorial" [4].

6.7.2 Flashing of FPGA

For a project containing LABCAR-MODEL-PMSM V4.x, it is necessary to flash
the model to the ES5340 board. This procedure is explained in detail in section
“Flashing Procedure” on page 89.

6.7.3 RTIO Modifications

The old version and LABCAR-MODEL-PMSM V4.x both offer the possibility to
have certain model output signals assigned to hardware output pins.
However, the DAC option changed with the introduction of V4.x in various man-
ners.
• At first, the DAC functionality is available for a different set of signals
now. Some signals, which have been eligible for DAC in V1.0, are not eli-
gible in V4.x anymore and vice versa. For a comprehensive overview
about the changes in the DAC functionality and other changes to the
input and output signals, refer to the tables in section “Parameters and
Interfaces” on page 129.
• At second, the way a DAC output is configured changed. The new proce-
dure to configure LABCAR-MODEL-PMSM DAC signals are described in
section “Analog Outputs” on page 119 and “PMSM DAC” on page 124. A
list of output signals that changed from V1.0 to V4.x is given below in
section “Parameters and Interfaces” on page 129.

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• With V1.0 the mapping of the signal onto the output pin was done by
providing minimum and maximum values for the signal and the output
voltage, whereby a scaling factor was calculated internally.
Now with V4.x you provide several factors to the system, which are used
to determine the output pin voltage. These factors are:
– a scaling factor
– an offset
– maximal output boundaries
– minimal output boundaries
• While with version V1.0, the RTIO configuration was immediately avail-
able in the project, LABCAR-MODEL-PMSM V4.x requires the loading of
the corresponding ADF-file. How to do this is described in section “Proj-
ect Creation in LABCAR-OPERATOR” on page 91.

6.7.4 License Information

The license information is provided in LABCAR-MODEL-PMSM V4.x via a
license key interface comprising 5 license keys. An indication whether the
license keys are valid is returned via a boolean output signal.
The license key interface is described in section “License Keys Interface” on
page 119.

6.7.5 Parameters and Interfaces

The following tables list all inputs, outputs and parameters of both model ver-
sions and highlights differences. Differences occur in existence, naming and
placement. Also false friends exist, whereby variables with identical or very sim-
ilar names can be found in both model versions but do not constitute the same
parameter with respect to its semantic meaning.

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6.7.5.1 Drivetrain

Inputs
Description Name (unit) Name (unit) V4.x Difference
V1.0
Load torque T_L (Nm) T_L (Nm) -
Initial mechanical rotor Phi_ mech_Init Phi_mech_Init -
angle (°) (rad)
Speed input of drivetrain Omega_ Omega_Input -
in speed mode mech_init (1/s) (rad/s)
Generated electrical - Torque (Nm) labeled as output of
engine torque PMSM in V4.x

Outputs
Description Name (unit) DAC Name (unit) DAC Difference
V1.0 V4.x
Mechanical rotor speed Omega_ mech yes Omega_ mech yes -
(1/s) (rad/s)
Electrical rotor speed Omega_el (°) yes Omega_el (rad/ yes -
s)
Mechanical rotor angle Phi_mech (°) yes Phi_ mech_rad yes -
(rad)
Electrical rotor angle Phi_el (°) yes Phi_el (rad) yes -
Resulting mechanical T_mech yes T_mech yes -
rotor torque (Nm) (Nm)
Average electrical torque - - Tel_average - non existent
(Nm) in V1.0

Parameters
Description Name (unit) V1.0 Name (unit) V4.x Difference
Friction coefficient of f (Nms/rad) f (Nms/rad) -
E-machine
Torsional stiffness C (Nm/rad) C (Nm/rad) -
between rotor and
load
Damping between D (Nms/rad) D (Nms/rad) -
rotor and load
Mode selector - Direct Feed non existent in V1.0
0: use torque input through
1: use speed input
Inertia of rotor J_E invJ_E In V4.x the inverse is given
(kgm^2) (1/kgm^2)
Inertia of load/drive- J_L invJ_L In V4.x the inverse is given
train (kgm^2) (1/kgm^2)

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6.7.5.2 Inverter

Inputs
Description Name (unit) Name (unit) V4.x Difference
V1.0
Input voltage of battery U_Batt0 (V) U_Batt0 (V) -
Intermediate circuit disable - RC_Ckt_Dis non existent in V1.0
flag able_Flag
0: Intermediate circuit enabled
1: Intermediate circuit disabled
Switch to connect/disconnect - Relay_Switch non existent in V1.0
battery
0: Battery disconnected
1: Battery connected
Input for resetting short circuit - ShortCircuit_ non existent in V1.0
error flags Flag_Reset
6 signals for IGBT control - PWM_*
6 signals for diode failure - Fail_Diode_* non existent in V1.0
IGBT Polarity Control Gate_Sig- Gate_Signal_Po- -
0: Low active, conducting while nal_Polarity larity
gate is "Low"
1: High active, conducting
while gate is "High"
6 signals for IGBT failure Fail_HS_X, Fail_IGBT_* -
Fail_LS_X
(X=U,V,W)

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Outputs
Description Name (unit) DAC Name (unit) V4.x DAC Difference
V1.0 V1.0 V4.x
Intermediate circuit U_CDCneu Yes U_DC (V) Yes -
voltage (V)
Battery current I_Batt (A) Yes I_Bat (A) No -
Intermediate circuit I_DC (A) Yes I_DC (A) Yes -
current
Voltage phase U u_phase (V) Yes U_phase_U (V) Yes -
Voltage phase V u_phase (V) Yes U_phase_V (V) Yes -
Voltage phase W u_phase (V) Yes U_phase_W (V) Yes -
Current through upper i_element (A) Yes I_element_H_U No -
switch phase U (A)
Current through upper i_element (A) Yes I_element_H_V No -
switch phase V (A)
Current through upper i_element (A) Yes I_element_H_W No -
switch phase W (A)
Current through lower i_element (A) Yes I_element_L_U No -
switch phase U (A)
Current through lower i_element (A) Yes I_element_L_V No -
switch phase V (A)
Current through lower i_element (A) Yes I_element_L_W No -
switch phase W (A)
Voltage on upper u_switch (V) Yes U_Switch_H_U No -
switch phase U (V)
Voltage on upper u_switch (V) Yes U_Switch_H_V No -
switch phase V (V)
Voltage on upper u_switch (V) Yes U_Switch_H_W No -
switch phase W (V)
Voltage on lower u_switch (V) Yes U_Switch_L_U No -
switch phase U (V)
Voltage on lower u_switch (V) Yes U_Switch_L_V No -
switch phase V (V)
Voltage on lower u_switch (V) Yes U_Switch_L_W No -
switch phase W (V)
Flag set if both upper - - Blocked_U - non existent in
and lower switches of V1.0
phase U are open
Flag set if both upper - - Blocked_V - non existent in
and lower switches of V1.0
phase V are open
Flag set if both upper - - Blocked_W - non existent in
and lower switches of V1.0
phase W are open

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Parameters
Description Name (unit) V1.0 Name (unit) V4.x Difference
Conducting voltage in U_D_Fwd (V) U_D_Fwd (V: -
diode (293.15K) 0.01...3)
Negative of U_T0_Diode - - non existent in V4.x
Inner resistance of battery R_Batt (  ) Inv_R_Batt Inverted in V4.x
(1/  : 1e-
3...10)
Inverse of intermediate cir- C_DC [mF] Inv_C_DC Inverted in V4.x
cuit capacitor (1/µF: 1e-3...1e-
1)
Switching time of IGBT T_Switch [s] T_Switch (s: -
0.2e-6...10e6)
Conducting resistance in R_SW_ON R_SW_ON -
IGBT ( ) (  : 0.00...0.05)
Conducting resistance in R-D_Fwd R_D_FWD -
diode ( ) (  : 0.00...0.05)
Conducting voltage in U_SW_Fwd U_SW_Fwd -
IGBT(293.15K) (V) (V: 0.01...3)

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6.7.5.3 PMSM

Inputs
Description Name (unit) Name (unit) V4.x Difference
V1.0
Stator coil resistance Rs Rs ( ) -
Resistance represents iron - Riron (  ) non existent in V1.0
losses of machine
Inductance in d-axis Ld (H) L_d (H) -
Inductance in q-axis Lq (H) L_q (H) -
Permanent magnetic flux in Psi (Vs) Psi_Rotor (Vs) -
rotor
Current DQ Selector - Current_DQ_Se- non existent in V1.0
0: Internally calculated values lector
for I_d and I_q are used.
1: Stimulus inputs "ID_Stimu-
late" and "IQ_Stimulate" are
used.
Stimulating input for I_d Ia_init (A) ID_Stimulate (A) -
Stimulating input for I_q Ib_init (A) IQ_Stimulate (A) -
Reset all internal states - Reset non existent in V1.0
Number of samples considered - AngleCorrectionS- non existent in V1.0
for angle correction of I_d and amples
I_q calculations
Rotor electrical angular fre-  Omega_el (rad/s) -
quency (1/s)
Electrical rotor angle X (rad) Phi_el (rad) -
3 strand failure inputs strang_fehler - non existent in V4.x
3 phase voltage inputs Uphase (V) - non existent in V4.x

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Outputs
Description Name DAC Name (unit) DAC Difference
(unit) V1.0 V1.0 V4.x V4.x
Voltage in d-axis - - Vd (V) - not provided by
V1.0
Voltage in q-axis - - Vq (V) - not provided by
V1.0
Flux in d-axis - - Psi_d (Vs) - not provided by
V1.0
Flux in q-axis - - Psi_q (Vs) - not provided by
V1.0
Motor electromagnetic Tel (Nm) Yes Torque (Nm) No -
torque
Induced back EMF of phase UP (V) Yes U_Ind_U (V) Yes -
U
Induced back EMF of phase Yes U_ind_V (V) Yes -
V
Induced back EMF of phase Yes U_ind_W (V) Yes -
W
Current of phase U Iphase (A) Yes I_Phase_U Yes -
(A)
Current of phase V - Yes I_Phase_V Yes -
(A)
Current of phase W - Yes I_Phase_W Yes -
(A)
Current in d-axis I_d (A) - ld (A) - -
Current in q-axis I_q (A) - lq (A) - -
Copper loss of motor P_loss_M - PLoss_Cop- - V1.0 only pro-
per (W) vides overall loss
value
Core loss of motor - - PLoss_Core - -
(W)
Current in core loss branch - - Icd (A) - not provided by
of d-axis V1.0
Current in core loss branch - - Icq (A) - not provided by
q-axis V1.0
Current in magnetization - - Imd (A) - not provided by
branch of d-axis V1.0
Current in magnetization - - Imq (A) - not provided by
branch of q-axis V1.0
Zero position (digital) Zero_Pos - - - not provided by
V4.x
Failure signal Failure_OF - - - Please contact
1: overflow of fk addition technical sup-
0: otherwise port if you need
assistance

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Parameters
Description Name (Unit) Name Difference
V1.0 (range) V4.x
Number of pole pairs p PPN (1...32) -
Peak value of cogging torque Tcm (Nm) - Cogging torque is not imple-
mented in V4.x

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7 LABCAR-MODEL-FC
ETAS LABCAR-MODEL-FC is a detailed model of a fuel-cell (FC) system, which
provides components to simulate the fuel-cell system in a fuel-cell solution. A
typical fuel-cell system consists of the following sub systems:
• Cathode Supply System
• Hydrogen Supply System
• Coolant Supply System
• Stack
You find an introduction to each sub system in “Fuel-Cell Subsystems and
Components” on page 155.
ETAS LABCAR-MODEL-FC is implemented in MATLAB/Simulink using S-Func-
tions. No additional toolboxes are required for the model execution. LABCAR-
MODEL-FC is targeting towards the automotive domain. The model is realtime-
capable and targeted for the execution on an ETAS LABCAR HiL system. Exe-
cution on other platforms may work as well. LABCAR-MODEL-FC includes LAB-
CAR-EE layers, so that a basic GUI is available.

7.1 Project and Experiment Creation

In the following section, the step-by-step guide describes the generation of a
COSYM and LABCAR-OPERATOR project using LABCAR-MODEL-FC. For the
execution of the project, no physical ECU is needed. Instead, a SoftFCCU con-
trols the fuel-cell system model. For providing the electrical and thermal power
requirements to the SoftFCCU, a basic restbus model of a vehicle is provided.
Please note that the SoftFCCU is a simplistic model prepared only for demon-
strating the behavior of the FC system by setting up control loops between FC
sub systems (Cathode, Anode, Coolant) and the SoftFCCU.

7.1.1 Project Creation in COSYM

This section addresses qualified personnel with knowledge in using COSYM. If
you do not have any experience in using COSYM, please read first [6].
For the manual project creation using LABCAR-MODEL-FC with COSYM follow
the steps described in this section.
To set up a COSYM project
1. Open the COSYM application.
The COSYM application can already have a project open, in
this case
2. Click File New  Project.
or
If no previous project is pre-loaded,
- Click the icon "Create new project".
3. Choose the location for the project and name the project.
4. Click Create.

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NOTE
Refer to section 7.1 in [6] for additional help regarding the project creation in
COSYM.

> The "Library" section of the project now is empty to start with.
A default system is created with the name "System" and is
automatically mapped to "HiL_Target".
To add a hardware module to a system
1. Open the "System" from the "Systems" pane by double click.
2. Expand "System".
3. Right click on "HiL_Target" and select "Create RTIO module"
from the drop-down menu.
> The "System" shows the added hardware module in the "Dia-
gram" view.
The fuel-cell system model consists of a single MATLAB/Simulink module. This
model comes with a SoftFCCU, which mimics very basic behavior of an FCCU
to get the fuel-cell system into operational mode.
To add a Simulink model for the FC_System
1. In the Library pane, right click on the "Control" folder and
choose "Import Model".
2. Under "Source of the model to be imported", click on the
Browse button.
3. Select the LMD file FC_System.lmd which internally refers to
the model configuration FC_System.mdl. The correspond-
ing LMD file FC_System.lmd is located in the installation
folder:
Project Items\COSYM\FC_Default_StackSoftFCCU
\mdl\Simulink_FC_System\src\FC_System_LABCAR
_rtw\
4. Click the Import button.
The model "FC_System" is added to the "Library" under the
"Control" folder.
5. Drag and drop the "FC_System" model from the "Library" pane
- to the "Diagram" area of the "System".
- to the "Units" folder of "System" under the "Systems" pane.
> The "System" shows the added module in the "Diagram" view.

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NOTE
The Simulink model references additional dependencies by using the
"ExternalFiles.xml". Please see section “Mapping External Files for HiL
Execution” on page 18 for further details.

The fuel-cell system model requires initial environment and gas conditions for
proper simulation. For this purpose, C-Code modules are used for temperature,
pressure and gas components initialization.
The following C-Code modules have to be added:
• InitializationTemperature.lmd
Located in the installation folder at
Project Items\COSYM\FC_Default_StackSoftFCCU\cmod\
InitializationTemperature\
• InitializationPressure.lmd
Located in the installation folder at
Project Items\COSYM\FC_Default_StackSoftFCCU\cmod\
InitializationPressure\
• InitializationGasComponent1.lmd
Located in the installation folder at
Project Items\COSYM\FC_Default_StackSoftFCCU\cmod\
InitializationGasComponent1\
• InitializationGasComponent2.lmd
Located in the installation folder at
Project Items\COSYM\FC_Default_StackSoftFCCU\cmod\
InitializationGasComponent2\
• InitializationGasComponent3.lmd
Located in the installation folder at
Project Items\COSYM\FC_Default_StackSoftFCCU\cmod\
InitializationGasComponent3\

To add a C-Code module

1. In the Library pane, right click on the "Environment" folder and
choose "Import Model".
2. Under "Source of the model to be imported", click on the
Browse button.
3. Select the C-Code module's LMD file from the locations speci-
fied above.
4. Click on the Import button.
5. The C-Code model is added to the "Library" under the "'Environ-
ment" folder.
6. Open the "System" from the "Systems" pane by double click.
7. Drag and drop the C-Code model from the "Library" pane
- to the Diagram area of the "System".

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- to the "Units" folder of "System" under the "Systems" pane.

8. Repeat the steps 1 to 7 for the 5 C-Code modules listed above.
> The "System" shows the added C-Code module in the "Dia-
gram" view.

By default, no model connections are established. For example, the SoftFCCU

is not connected to the restbus or fuel-cell system model. Pre-defined connec-
tion files couple the restbus, SoftFCCU and fuel-cell system.
The following connection files can be added:
• FC_Default__SoftFCCU.xml
• Restbus__FC_Default_viaInitialValues.xml
• Restbus__SoftFCCU.xml
• SoftFCCU__FC_Default.xml
These files are located in the installation folder at
Project Items\COSYM\FC_Default_StackSoftFCCU\conn
To add connection files
1. Open the "Connections" view available at the bottom of the
opened "System".
2. Click on the "Import connections" icon.
3. Select each XML file mentioned above.
4. Click on "Import" to import connections from each file.
5. Repeat the steps 1 to 4 for all the connection files mentioned
above.

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> After the connection files are added, the necessary connec-
tions are established between the Fuel-Cell system, SoftFCCU,
and restbus. They are visible in the "Connections" view.

Fig. 7-1 COSYM Connections View for FC-System

Fig. 7-2 COSYM Diagram View with Connections for FC-System

NOTE
Check each connection file and ensure that you added all connection files.
Otherwise, the COSYM project might not work properly.

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OS Configuration
Via the "Deployment" view, you can organize the processes of COSYM mod-
ules. For Simulink modules, the order of execution and the selection of a proper
step size is important. By default, tasks are not auto-generated for Simulink
modules when adding them to the project. Please click on + Auto mapping to
automatically map the processes to tasks. For added C-Code modules, ensure
that the timer processes under tasks are executed before the Simulink model
processes as shown in Fig. 7-3.

Fig. 7-3 Execution of Timer Processes

NOTE
Please refer to [6] section "OS Configuration" - "Ordering of the Tasks" to get
familiar with the ordering of processes.

All relevant modules, necessary connections, and the OS configuration are now
available and you can build a COSYM project.

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To build a COSYM project

1. Choose "Project" "Build and Run".
2. Click Build and Run.

For more details about the Simulink code generation, refer to the section “Sim-
ulink Model - Code Generation Process” on page 14.

7.1.2 Project Creation in LABCAR-OPERATOR

This section addresses qualified personnel with knowledge in using LABCAR-
OPERATOR. If you do not have any experience in using LABCAR-OPERATOR,
please read first [1].
For the manual project creation using LABCAR-MODEL-FC with LABCAR-OPER-
ATOR follow the steps described in this section.
To set up the LABCAR-OPERATOR project
1. Open the LABCAR-IP application.
2. Click File  New Project.
3. Choose the location for the file and name the project.
4. Use "RTPC" as "Target Name".
5. Click Finish.
> The Project Explorer contains an empty hardware configura-
tion.
The fuel-cell system model consists of a single MATLAB/Simulink module. This
model includes a SoftFCCU, which very basically mimics the behavior of an
FCCU in order to bring the fuel-cell system into operational mode.
To add a Simulink model for FC_System
1. Choose Project  Add Module.
2. Select "Add Simulink (TM) Module".
3. Select "Use existing Simulink (TM) Model (will be copied)".

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4. Select the fuel-cell system model configuration FC_System.

The corresponding model FC_System.mdl is located in the
install folder
Project Items\LCO\FC_Default_StackSoftFCCU\
mdl\Simulink_FC_System\src
5. Activate the checkbox "Copy Model Directory into Project".
6. Click Finish.
> The Project Explorer shows the added model.
The fuel-cell system model requires initial environment and gas conditions for
a proper simulation. For this purpose, C-Code modules are used for tempera-
ture, pressure and gas components initialization.

NOTE
The Simulink model references additional dependencies by using the
"ExternalFiles.xml". Please see section “Mapping External Files for HiL
Execution” on page 18 for further details.

The following C-Code modules have to be added:

• InitializationTemperature.lmd
Located in the installation folder at
Project Items\LCO\FC_Default_StackSoftFCCU\cmod\
InitializationTemperature\
• InitializationPressure.lmd
Located in the installation folder at
Project Items\LCO\FC_Default_StackSoftFCCU\cmod\
InitializationPressure\
• InitializationGasComponent1.lmd
Located in the installation folder at
Project Items\LCO\FC_Default_StackSoftFCCU\cmod\
InitializationGasComponent1\
• InitializationGasComponent2.lmd
Located in the installation folder at
Project Items\LCO\FC_Default_StackSoftFCCU\cmod\
InitializationGasComponent2\
• InitializationGasComponent3.lmd
Located in the installation folder at
Project Items\LCO\FC_Default_StackSoftFCCU\cmod\
InitializationGasComponent3\

To add a C-Code module

1. Choose Project  Add Module.
2. Select "Add C-Code Module".
3. Select "Use existing Module (will be copied)".
4. Select one of the C-Code modules listed above.
5. Click Finish.

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6. Repeat the steps 1 to 5 for all the five C-Code modules listed
above.
> The Project Explorer shows the added C-Code modules.
By default, no model connections are established. For example, the SoftFCCU
is not connected to the restbus or fuel-cell system model. Pre-defined connec-
tion files couple the restbus, SoftFCCU and fuel-cell system.
The following connection files can be added:
• FC_Default__SoftFCCU.xml
• Restbus__FC_Default_viaInitial_Values.xml
• Restbus__SoftFCCU.xml
• SoftFCCU__FC_Default.xml
These files are located in the installation folder at
Project Items\LCO\FC_Default_StackSoftFCCU\conn
To add connection files
1. Open the "Connection Manager" and right-click in the area
"Existing Connections".
2. Select "Import Connections…" from the drop-down menu.
3. Select each connection file mentioned above.
4. Click on "Open" to import connections from each file.
5. Repeat the steps 1 to 4 for all the connection files mentioned
above.
> After the connection files are added, the necessary connec-
tions are established between the fuel-cell system, SoftFCCU,
and restbus and they are visible in the "Connection Manager".

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NOTE
Check each connection file and ensure that you added all connection files.
Otherwise, the project might not work properly.

OS configuration
Via the "OS Configuration" tab, you can organize the processes of LABCAR-
OPERATOR modules. For Simulink modules, the order of execution and the
selection of a proper step size is important. By default, proper tasks for the Sim-
ulink model are auto-generated when adding the module to the project. For
added C-Code modules you have to assign the execute processes manually to
ensure that the timer processes under tasks are executed before the Simulink
model processes as shown below. Please ensure that "Init" processes are
assigned to the "Init" task. In most cases, this happens automatically.

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NOTE
Please refer to LABCAR-OPERATOR User's Guide [1] section 3.15.2 "Working
with OS Configurations" to get familiar with the ordering of processes.

All relevant modules, necessary connections, and the OS configuration are now
available.
As a next step, you can build the LABCAR-OPERATOR project.

NOTE
Be sure to select the proper MATLAB version using the MATLAB Version
Selector. See [2].

To build a LABCAR-OPERATOR project

1. Choose Project Build.
2. Activate the code generation for the "FC_System" module.
3. Click Build.
For more details about Simulink Code Generation, refer to the section “Simulink
Model - Code Generation Process” on page 14.

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7.1.3 Experiment Creation

After the successful build of the project in COSYM or LABCAR-OPERATOR, you
can prepare the experiment for the first execution of the simulation model.
Starting point is an empty experiment.

Mapping Files
"Mapping files" provide a possibility to simplify the signal handling in LABCAR-
EE. For LABCAR-MODEL-FC various signal mappings are pre-defined. This
allows a simple access to most important simulation signals without in-depth
knowledge of the model.
1. Open Experiment Explorer.
2. Add all mapping files located in the install folder at
Project Items\LCO\FC_Default_StackSoftFCCU\
mapping

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NOTE
Ensure that the added mapping files are also activated.

Parameter Files
No parameter files are provided. The default values of the Simulink model are
used.

Layers
The "Layer" provides the basic interface to handle the vehicle model. It allows
the setting of the driver mode and the selection of pre-defined cycles. As a pre-
liminary step, you can copy images for the layer from the installation folder.
To import layers
1. Copy images located in install folder at
Project Items\LCO\FC_Default_StackSoftFCCU\
img.
2. Create the target folder if it does not already exist in the Exper-
imentation folder and name it as "Image_Files".
3. Paste the images copied in step 1.

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4. Import the FuelCell_Overview.layer file as located in

Project Items\LCO\FC_Default_StackSoftFCCU\
gui.

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After the successful import of the FuelCell_Overview.layer, basic dash-

boards for handling the fuel-cell system model exist.

NOTE
All pre-defined instruments use mapped signals provided by the mapping
files. For proper execution, add all mapping files to the experiment.

NOTE
Consider that only default LABCAR-EE instruments are used. You can adapt
the layer individually to your needs.

All required artifacts for the first execution of the models are added to the
experiment. With that, the experiment is ready for the download to RTPC and
the simulation. The section “Getting Started with the Tutorial Project” on
page 151 describes the handling of the simulation model in more detail.

7.2 Getting Started with the Tutorial Project

The following tutorial gives an introduction on how to use LABCAR-MODEL-FC.
Within this tutorial LABCAR-MODEL-FC is used to represent an automotive fuel-
cell system. A physical control unit is not required, since the SoftFCCU of LAB-
CAR-MODEL-FC will be used to control the model.

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The tutorial project is located in .\Example Project.

NOTE
Please do not open or manipulate the example project in the installation
folder directly. Instead, copy the example project from the installation folder
to a location of your choice.

7.2.1 Overview
The provided graphical user interface for LABCAR-MODEL-FC contains basic
functionality to operate the vehicle model comfortably. The GUI allows to select
different operation modes to stimulate the fuel-cell system model. Basic
observables about the operation of fuel-cell system, actuators, and SoftFCCU
are presented graphically.

• The upper row in the overview represents the most significant measure-
ment quantities within the fuel-cell system. They include information
about the stack and corresponding supply systems, namely hydrogen,
air and the coolant supply system.
• The "User Interface" section provides controls to stimulate the fuel-cell
system. After selecting the cycle mode, you can stimulate the fuel-cell
system by interacting with the available controls. The section “User Inter-
face” on page 157 describes the individual control elements.
• The section "FCCU" shows the requested current and the status of the
Shut-Off valves. Moreover, most important SoftFCCU parameters are
given, to adapt the applied operation strategy of the FCCU.

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• The lower row in the overview represents the status of the actuators in
the supply systems. In detail, these are the rotational speeds of the
pumps, blower, and compressor as well as valve positions.

NOTE
The GUI uses standard instruments of LABCAR-EE and an open-source RT-
Plugin to extend functionality of the instruments. This can easily be used as a
template for individual GUIs.

7.2.2 Manual Control of Humidifier and Bypass

Humidifier and bypass are closed by default. They are controlled manually by
using the manual settings in the section "FCCU" of the GUI. You can perform
according adjustments via the inputs "Humidifier Control" and "Bypass Control"
of the SoftFCCU. Both parameters are normalized actuator inputs. Hence, valid
values are between zero and one. By that, cathode bypass and humidifier can
be activated or deactivated.

Fig. 7-4 Manual Setting Section to Activate or Deactivate Cathode

Humidifier and Bypass

7.2.3 Adaptation of the Operation Strategy

The stack temperature gradient and the oxygen stoichiometry are key entities
to characterize the operation strategy applied to a system. They influence the
water management and the efficiency of the electro-chemical reaction inside
the fuel cells. The SoftFCCU has a default strategy implemented, which you can
revise and change. For that, the "FCCU" section of the GUI contains inputs for

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the "Stack Temp. Gradient" and "Oxygen Stoichiometry". Both values depend on
the current operation state. Hence, instead of scalars, one-dimensional maps
exist, which depend on the requested stack current.

Fig. 7-5 Manually Adapted Setting for the Operation Strategy of the
SoftFCCU

After you adjusted the values, press "Apply" to activate your changes. With that,
the SoftFCCU calculates new desired values for the operation of the stack, e.g.
by adapting the oxygen or coolant mass flow. Based on the physical represen-
tation of the stack, the expected influence on the stack can be revised.
Example: You can increase the desired oxygen stoichiometry using the instru-
ment. When applying the changes to the SoftFCCU, the rotational speed of the
air compressor should increase accordingly. More air mass flow is provided to
the stack. A positive influence on the stack efficiency can be expected. The
stack voltage raises.

Fig. 7-6 Increasing/Decreasing Stack Voltage

The effect of a changed operation strategy can be revised by the reaction of the
fuel-cell stack, e.g. an increasing or decreasing stack voltage.

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7.3 Fuel-Cell Subsystems and Components

The current version of LABCAR-MODEL-FC includes a single reference system
configuration. It demonstrates how to use the individual components. Different
connections of the components are possible, so that other FC system topolo-
gies are feasible as well.

7.3.1 Cathode Supply System

The cathode supply system feeds oxygen to the stack. It consists out of a sin-
gle stage compressor driven by an e-machine. It contains an intercooler,
humidifier, and a stack bypass for further control interactions. The model archi-
tecture is given in Fig. 7-7.

Fig. 7-7 Cathode Supply System Components View

Please refer to the Model Reference document section 2 for a detailed descrip-
tion of the cathode supply system and its components including a description
of the complete interface.

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7.3.2 Hydrogen Supply System

The hydrogen/anode supply system feeds hydrogen to the stack. It consists of
a supply path and a recirculation loop. The supply path contains a hydrogen
tank, pressure reducer, and a hydrogen gas injector. The recirculation loop con-
tains a water separator as well as a recirculation blower. An additional purge
valve is available and rejects inert gases to the ambient.

Fig. 7-8 Hydrogen Supply System Components View

Please refer to the Model Reference document section 4 for a detailed descrip-
tion of the hydrogen supply system and its components including a description
of the complete interface.

7.3.3 Coolant Supply System

Fuel-cell stacks generate a notable amount of waste heat at increasing current
densities. Nevertheless, the low stack temperature limits the heat rejection via
exhaust gas and heat exchange with the ambient temperature. A separate cool-
ing subsystem is required and the provision of sufficient cooling power is a cen-
tral point in the functional development as well as the system design.

Fig. 7-9 Coolant Supply System Components View

Please refer to the Model Reference document section 3 for a detailed descrip-
tion of the coolant supply system and its components including a description
of the complete interface.

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7.3.4 Stack
LABCAR-MODEL-FC represents a 1-D+1-D fuel-cell stack model. The model
includes a 1-D membrane model for a detailed description of the membrane
resistance, water content, and the resulting water exchange between the elec-
trodes. Furthermore, a spatial distributed 1-D bipolar plate and gas channel
model is used to consider the non-linear characteristics, e.g. temperature, cur-
rent, and pressure variations along the stack. Especially automotive relevant
phenomena, e.g. influence of subfreezing temperatures, are considered.
The following features are regarded:
• Single cell model with a detailed loss behavior considering the affect of
current, temperature, reactant stoichiometry, and membrane humidity
on cell voltage
• Detailed calculation of water content and water exchange based on a 1-
D membrane model
• 1-D multi-component gas channel model allows the specification of indi-
vidual gas composition for each electrode
Simple to define pressure loss characteristics
• Simulation of different flow field designs
Co/Counter flow setups with support of internal cell humidification
• Realistic cold start-up behavior based on membrane's temperature
model, non-linear dynamics of the cells water content, and temperature
dependent fluid properties
• Two-phase water model considering accumulation and movement of
liquid water in the gas channel
Please refer to the Model Reference document section 5 for a detailed descrip-
tion of the fuel-cell stack and its components including a description of the
complete interface.

7.4 User Interface

The provided graphical user interface for LABCAR-MODEL-FC contains basic
functionality to comfortably operate the fuel-cell model. The GUI enables you to
either set a desired vehicle speed manually, use external stimulation or use a
pre-defined cycle. The fuel-cell model is controlled by a basic fuel-cell control
unit, which will get the demanded current as a request. Furthermore, the GUI
provides a native instrument to observe the current condition of the fuel-cell
model.

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7.4.1 Overview
Operating and observing is the main focus, such that the GUI represents the
instrumentation for user interaction and measuring instrumentation to observe
several effects. Therefore, the GUI is arranged in several sections as the follow-
ing image demonstrates.

The upper row in the overview represents the most significant measurement
quantities within the fuel cell between corresponding supply systems and the
stack.
• The sections "Tank", "Anode Subsystem", "Fuel Cell Stack", "Cooling Sub-
system", and the "Cathode Subsystem" show the current condition of the
fuel-cell model by demonstrating temperatures, pressures, stoichiome-
try, humidity, and mass flows.
• With the section "User Interface" you are able to start the fuel-cell sys-
tem, to manually set a desired vehicle speed, or to choose a drive cycle.
The vehicle speed is mapped\translated to the current request based on
a simple mapping table. There is no dedicated vehicle model.
• The section "FCCU" shows an overall identification of the system.
• With the bottom sections "Anode Subsystem Actuators", "Cooling Sub-
system actuators", and "Cathode Subsystem actuators" you are able to
observe the operation behavior of the actuators while operated by the
SoftFCCU.

7.4.2 GUI Section User Interface

The section "User Interface" allows to operate the fuel-cell model.
You can choose from the drop-down list several operation modes. The pre-
defined modes are:

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• Manual:
You can set the vehicle speed either by moving the slider or by directly
entering the vehicle speed in the input field.
• External:
You can set a user-defined vehicle speed trajectory which will be fol-
lowed.
• Cycle:
You can choose from pre-defined driving cycles. If the mode "Cycle" is
selected, the "Cycle" drop-down list applies. Here you can choose a driv-
ing cycle of interest.
Pre-defined cycles are:
– WLTP
– User defined
– Off

7.4.3 GUI Sections for Observation

The upper sections of the GUI provide the basic information about the anode
supply system, the cathode supply system, the cooling supply system, and the
fuel-cell stack.
• Tank
The tank is part of the anode supply system and indicates the current
hydrogen level; additionally it displays how much hydrogen is flowing to
the anode.
• Anode Subsystem
This section provides the information about the anode side of the fuel
cell. Typically, a pressure sensor observes the pressure at the intake
manifold. Furthermore, it shows the humidity, the stoichiometry at the
anode, and how much hydrogen is provided to the anode.
• Fuel Cell Stack
This section provides general stack information. You can observe the
current water content within the stack and also the voltage level at the
electrical stack terminal. As an indication in which operation range the
fuel cell is operating, the current efficiency is demonstrated.

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• Cooling Subsystem
During operation, the generated heat within the stack has to be trans-
ported. You can observe the current temperatures at the intake manifold
and the outtake manifold of the cooling supply system.
• Cathode Subsystem
This section provides the information about the cathode side of the fuel
cell. Typically, a pressure and a temperature sensor observe the condi-
tions at the intake manifold. Furthermore, it shows the humidity, the stoi-
chiometry at the cathode, and how much oxygen is provided to the
cathode.

The lower sections of the GUI provide basic information about the actuators of
the corresponding supply system. The GUI contains illustrations for the main
components. These components are:
• Hydrogen Recirculation Blower (Anode Supply System)
• Hydrogen Injector Valve (Anode Supply System)
• Compressor (Cathode Supply System)
• Mass Control Valve (Cooling Supply System)
• Radiator (Cooling Supply System)
• Pump (Cooling Supply System)
You can observe several actuators. The valves are observed by demonstrating
their current position. The compressor, the hydrogen recirculation blower, and
the pump are observed by demonstrating their shaft speed when actuated by
the SoftFCCU. The following picture shows this specific section.

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ETAS Licensing

8 Licensing
The simulation models of the LABCAR-MODEL product family possess a
license protection. Each product of the LABCAR-MODEL family requires its own
license and refers to a specific version. The actual mechanism differs between
FPGA-based and Simulink-based models; they are described in the following
sections.

8.1 FPGA-Based Simulation Models

The LABCAR-MODEL-PMSM runtime license is generated based on the serial
number of the ES5340.2M board. The serial number can be obtained from the
"HSP" tool using the "Hardware" window. A Runtime license file consists of val-
ues (Hexadecimal) for the model license inputs "Lic_0", "Lic_1", "Lic_2", "Lic_3"
and "Lic_4". A LABCAR-EE layer "PMSM_Runtime_License" is available to enter
runtime license keys. Nevertheless the following mechanism can be used to
apply license values.
• Browse "RTPC/Hardware/_.../Es5340flexiblefpga" in LABCAR-EE to
access the model license inputs.
• Use the "Signal-Calibrate Constant Value"option to edit input values.
• Change the data representation from decimal to hexadecimal for "Edit
Box" of every model license input.
• Provide the license values given in the runtime license file for "Lic_0" to
"Lic_4".

8.1.1 License Status Information

You can retrieve the licensing status in the LABCAR-EE from model license out-
put "Lic_out". "Lic_out" is "1" or "License Status" is green in "PMSM_Runtime_Li-
cense" layer if correct license values are set for model license inputs. Otherwise
it is "0" or the "License Status" is Grey.

8.2 Simulink-Based Simulation Models

Two types of licenses exist for the Simulink-based simulation models. They
are:
• A Runtime License ("RT-License") permits the execution of a model con-
taining one or more S-Function blocks from LABCAR- MODEL, irrespec-
tive of the underlying platform (e.g., Windows or ETAS RTPC).
• An Operator License permits the code-generation of a model containing
one or more S-Function blocks from LABCAR-MODEL. In addition, it per-
mits the execution of a model.
On Windows machines, the ETAS License Manager is used to verify the LAB-
CAR-MODEL license.
You find the procedure to install license files on ETAS RTPC in the LABCAR-
OPERATOR documentation [5].

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ETAS Licensing

8.2.1 License Status Information (Windows)

The license status is given in the ETAS License Manager. The MATLAB com-
mand window also reports the licensing status. An error occurs, if the ETAS
License Manager is not able to find a valid license or when the license checkout
fails. In this case, the error message is written to the MATLAB command win-
dow. The error message includes details about the S-Function, which caused
the error.

8.2.2 License Status Information (RTPC)

When using ETAS RTPC as simulation target, the license status is printed to the
hardware output of LABCAR-EE during the model initialization. The level of
detail of the printed messages is determined by the logging level of the RTPC.
Please see [5] for further information.

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ETAS Glossary

Glossary
This section explains technical terms used in this manual. The abbreviations
and terms are listed in alphabetic order.

Abbreviations

BMS
Battery Management System, i.e., the ECU that controls an automotive
battery.
ECU
Electronic Control Unit
EMF
Electromotive Force
EMS
Engine Management System, i.e., the ECU that controls the combustion
engine
FPGA
Field Programmable Gate Array
FC
Fuel Cell
FCCU
Fuel Cell Control Unit
FMU
Function Mock-up Unit
GUI
Graphical User Interface
HiL
Hardware-in-the-Loop
HSP
Hardware Service Pack
ICE
Internal Combustion Engine
IGBT
Insulated Gate Bipolar Transistor
LCRT
LABCAR-RUNTIME
MCU
Motor Control Unit, i.e., an ECU that controls an electrical motor
MiL
Model-in-the-Loop
OSS
Open Source Scan

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ETAS Glossary

PEM
Polymer Electrolyte Membrane
PMSM
Permanent Magnet Synchronous Motor; an electrical motor

PWM
Pulse Width Modulation
SiL
Software-in-the-Loop
SUT
System Under Test
VVTB
Virtual Vehicle Test Bench
XiL
X-in-the-Loop; X is a placeholder for H, S, or M. XiL is the superset of MiL,
SiL, and HiL solutions.

Terms

Offline Parametrization
Executing the simulation in LABCAR-EE. The unit under test, either a
physical or a virtual ECU, is disconnected (hence "offline"). The set with
the parametrization is stored in a supported parameter file.
Online Parametrization
The unit under test, either a physical or a virtual ECU, is connected
(hence "online"). The project is linked to the parameter file from the
offline parametrization. The simulation is running.

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ETAS References

References
For more information refer to the following documents that are part of the doc-
umentation package of LABCAR-OPERATOR.

[1] LABCAR-OPERATOR V5.4.10 User´s Guide

[2] LABCAR-OPERATOR V5.4.10 Software Compatibility List
[3] ES5340.2 Electric Drive Simulation Board User's Guide
[4] FlexibleFPGA V3.0.0 - Workflow Description: Tutorial
[5] ETAS RTPC User´s Guide

For more information refer to the following documents that are part of the doc-
umentation package of COSYM.

[6] COSYM V2.3.0 User's Guide

[7] COSYM_V2.3.0_Software_Compatibility_List

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ETAS Figures

Figures
Fig. 2-1 General Parametrization Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Fig. 2-2 Online Parametrization Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Fig. 2-3 LCInports and LCOutports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Fig. 2-4 Code Generation Process for Simulink Models . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Fig. 2-5 Exemplary Version Information for an S-Function . . . . . . . . . . . . . . . . . . . . . . . . .18
Fig. 4-1 COSYM Connections View for VVTB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Fig. 4-2 COSYM Diagram View with Connections for VVTB . . . . . . . . . . . . . . . . . . . . . . . .31
Fig. 5-1 COSYM Connections View for VVTB_ICE_LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Fig. 5-2 COSYM Diagram View with Connections VVTB_ICE_LC . . . . . . . . . . . . . . . . . . . .67
Fig. 5-3 Execution of Timer Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Fig. 6-1 "Signals" Tab Analog-Out-Mux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Fig. 6-2 "Data" Tab Analog-Out-Mux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Fig. 6-3 LABCAR-MODEL-PMSM Model Interface Overview . . . . . . . . . . . . . . . . . . . . . . .120
Fig. 7-1 COSYM Connections View for FC-System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Fig. 7-2 COSYM Diagram View with Connections for FC-System . . . . . . . . . . . . . . . . . .141
Fig. 7-3 Execution of Timer Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Fig. 7-4 Manual Setting Section to Activate or Deactivate Cathode Humidifier and Bypass
153
Fig. 7-5 Manually Adapted Setting for the Operation Strategy of the SoftFCCU . . . . . .154
Fig. 7-6 Increasing/Decreasing Stack Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Fig. 7-7 Cathode Supply System Components View . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Fig. 7-8 Hydrogen Supply System Components View . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Fig. 7-9 Coolant Supply System Components View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156

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ETAS Contact Information

Contact Information
ETAS Headquarters
ETAS GmbH

Borsigstraße 24 Phone: +49 711 3423-0

70469 Stuttgart Fax: +49 711 3423-2106
Germany Internet: www.etas.com

ETAS Subsidiaries and Technical Support

For details of your local sales office as well as your local technical support
team and product hotlines, take a look at the ETAS website:

ETAS subsidiaries Internet: www.etas.com/en/contact.php

ETAS technical support Internet: www.etas.com/en/hotlines.php

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