At the Valeo R&D center in Créteil, France, developing and testing new algorithms and control strategies previously required a physical prototype test bench. This approach was costly and timeconsuming, as it typically involved writing and executing extensive computer code, while also demanding programming expertise from the development engineers. Due to limited flexibility, engineers were unable to adjust or modify control loops in a timely manner, making troubleshooting more difficult.

Realtime simulation platform integrated with Simulink 

Valeo had already been using Simulink for preliminary R&D testing. Building on this, the RT‑LAB Rapid Control Prototyping Drive System (RCP‑Drive) enabled users to automatically load Simulink models onto a real‑time simulation platform configured with the required I/O interfaces for the project—such as PWM, voltage/current sensors, speed encoders, etc.

Using the RCP solution, mathematical models could be automatically imported from MATLAB/Simulink into a real‑time simulator equipped with I/O interfaces before being connected to the actual system. This allowed controller functionality to be rapidly demonstrated in a simulated test environment, ensuring smooth and fast project execution.

By adopting the RTLAB realtime simulation platform, Valeo significantly reduced both time and cost, creating opportunities for other industrial projects within the company. The quicktouse HumanComputer Interface (HCI) and data logging solution enabled engineers to drill down into problem details more rapidly, without needing additional tools.

More accurate and flexible 

The PulseWidth Modulation (PWM) management system is fast and precise, and the PWM signals can be modified directly within Simulink software. This flexibility allows users to perform indepth testing. By experimenting with new control rules, Valeo was able to demonstrate new electricvehicle concepts and address modern market challenges. 

Key advantages include:
■ Innovative technology synchronizes generated PWM signals with ADC (AnalogtoDigital Converter) data acquisition, preventing signal sampling during switching events and avoiding interference.
■ Powerful “resolver input” capability acquires sine and cosine signals from an actual resolver and converts them into position information for the model.

The RCP functionality substantially reduced development time by enabling immediate error correction during the early stages of product development. By previewing the product at an early design phase, engineers could identify and correct potential mistakes and make adjustments to the product, thereby avoiding further costly setbacks.

The RTLAB rapid prototyping solution is tailored to the needs of motor control, various motor types, and powerconversion topologies:

■ The system can connect to thousands of I/O channels to simulate complex systems (PCI Express bus).
■ Proprietary FPGA technology delivers higher simulation performance, accuracy, and greater flexibility in data acquisition.
■ Unique realtime simulation software enables model editing, visualization, and test automation.
■ The open architecture of the RTLAB realtime simulation platform supports seamless integration with thirdparty components.

MCUHIL – Motor Control Unit HardwareintheLoop Testing 

■ Highfidelity motor simulation models capable of simulating rotor asymmetry, harmonic backEMF, magnetic saturation, IGBT deadtime effects, etc.
■ Latency from external controller PWM signal acquisition to motor current signal output is less than 1.3 μs when testing critical protection circuits.
■ Supports realtime simulation of native MATLAB/Simulink models. 

MCU-PRCP功率级快速控制原型电机控制器解决方案MCUPRCP – PowerStage Rapid Control Prototyping Motor Controller Solution 

■ Supports seamless integration with MATLAB/Simulink and automatic code generation.
■ Enables rapid control prototyping at the powerstage level.
■ Supports modular hardware expansion. 

MCUPHIL – PowerStage HardwareintheLoop Motor Controller Solution

■ Inputtooutput delay of the linear switching simulator is less than 10 μs.
■ Overload capability up to 8 times the rated power.
■ Can be directly connected to frequency converters.