Exploratory testing of Washing Machine using Hardware-in-Loop Testing
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Exploratory testing of Washing Machine
using Hardware-in-Loop Testing
Akshay P Chouhan
GTEC, Whirlpool
Myrtle Binil R
ETAS Automotive India Private Limited
1 Confidential | ETAS | Whirlpool | 2014-04-14| All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Agenda
Introduction
Washing Machine Validation- Challenges
Hardware in Loop Testing for Washing Machine
Plant Model – For closed loop testing
Advantages
Summary
2 Confidential | ETAS | Whirlpool | 2014-04-14| All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Introduction
– Product Life Cycle
Requirement Design &
Validation
Specification Coding
SOP
– Validation refers to set of tasks that ensures the component is build as per
the specification.
– In Whirlpool,
– These validations are done manually
– Validation are done with real prototypes
3 Confidential | ETAS | Whirlpool | 2014-04-14| All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.
Washing Machine Validation – Challenges
– Difficulty to test different sequence of test case in the real prototype.
– Difficulty to generate different test conditions such as
– Eg: Testing over flow error
– For this user have to tweak the sensor signal in precise manner
– Wait until the overflow occurs in the machine (This also requires to disconnect the
feedback signals to the controller which will lead to some other diagnostic errors)
– More features into washer, complex functionality
Advanced touch interface control
Simple rotary type control
Early ’90s Later 2000’s
4 Confidential | ETAS | Whirlpool | 2014-04-14| All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.Washing Machine Validation – Challenges
– Standards and safety features in the washer make the software complex
and therefore thorough validation w.r.t these should be done to get the
product certified.
– More intelligence in the product increase the complexity of diagnostics
routines which is time consuming to test manually
– Expensive prototypes for testing
– Time to market
– On-Time delivery of product
– Quality of product
5 Confidential | ETAS | Whirlpool | 2014-04-14| All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.Washing Machine Validation – Overcoming the challenges
– To overcome these challenges in validation, hardware in the loop testing
concept which is widely used in automotive industry was explored.
– With the help of ETAS, the possibilities are studied and this brought
sufficient improvement in testing w.r.t quality of testing and time.
– ETAS DESK-LABCAR system with efficient signal conditioning unit was used
for testing the washer.
– ETAS LABCAR automation software was used to automate the test cases for
washer.
– ETAS Variant Management system was used to manage different variants of
washer of same hardware platform.
6 Confidential | ETAS | Whirlpool | 2014-04-14| All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.Hardware in Loop Testing for Washing Machine
Design
WIDE protocol
The main control unit of Proprietary to whirlpool
washing machine
AC mains
User Interface
Control Unit
WIDE Panel
Actuators Sensors
Real Loads User interface panel, where all user
controls are presents
(Like knobs, touch screen controls)
Signal Conditioning
Signal conditioning unit for AC to DC
isolation
Acquisition Generation
IO Card
Modules IO Cards
Simulink Plant
Other Process
Model
Real Time Controller
Real time controller
7 Confidential | ETAS | Whirlpool | 2014-04-14| All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.Hardware in Loop Testing for Washing Machine
Design Realization
ETAS DESK-LABCAR system as shown below is used to realize the design
– In Mini-LABCAR, PCIe based
Control Unit Multi-IO card ES5340
Master and Slave are used
to simulate and acquire
Signal Conditioning Unit different signals of control
unit.
WIDE
– Signal Conditioning unit
Break out Box acts as a isolation between
AC and DC signals and
signal conversion
ES5340 Multi-IO Cards IP EE
– In LCO-EE, interface is
Host PC developed to communicate
Real Time PC with the WIDE interface
8 Confidential | ETAS | Whirlpool | 2014-04-14| All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.Plant Model – For Closed Loop Testing
– To cover most of the test cases during validation, a closed loop setup is required.
– This is achieved by developing a plant model of washer in MATLAB®/Simulink and
integrating this to LABCAR
– With the different features of Simulink modeling, a structured mathematical model of
washing machine was developed in short duration.
Washing machine functionality
Math model of washing machine
components
Parameter
-Washing Machine
-Environmental
Interface to LABCAR components
9 Confidential | ETAS | Whirlpool | 2014-04-14| All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.Plant Model – For Closed Loop Testing
Water Inlet :
Functionalities of inlet pipe for hot
water, cold water, steam fill etc.
Temperature Control :
Maintaining the temperature based on
heater status, water temperature
Drum Model :
All functionalities related to drum
such as cloth soaking, agitation etc..
Drain Control :
All functionalities related to draining
of water from the washer.
Switches:
Simulation of all kind of switches
related to washer, such as lid lock, lid
close etc...
Detergent Dispense:
The detergent dispense module
model, containing all the functionality
to dispense the detergent
10 Confidential | ETAS | Whirlpool | 2014-04-14| All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.Plant Model – For Closed Loop Testing
In the same manner, all the sensors are also modeled and integrated in the LCO-IP
Different Sensor Models
Washer Plant Model
– With this a structured way of development and integration was possible
– The actuator models were also integrated into the system, on need
11 Confidential | ETAS | Whirlpool | 2014-04-14| All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.Plant Model – For Closed Loop Testing
The complete flow of system
Electrical
Physical Quantity
Sensor Value LABCAR IO
Models ES 5340
Signal Control
Plant Model Conditioning Unit
Electrical
Value
Actuator LABCAR IO
Physical Quantity models ES 5340
ETAS Real Time PC
WIDE
Communication
Host PC
12 Confidential | ETAS | Whirlpool | 2014-04-14| All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.Advantages
Testing of different conditions are now simple with click of buttons
– Example: Overflow Error check
– Stuck conditions on inlet value will continuously fill water into the drum. This creates the
over flow error, which can be validated very easily and in precise manner
Inlet stuck
subsystem
Simulation of stuck with
LCO -EE
– Example: Invalid Pressure
– Providing an invalid pressure to the system and verifying the behavior is also simple by click
of button, by overriding the actual values from plant
Overriding
pressure
value
13 Confidential | ETAS | Whirlpool | 2014-04-14| All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.Advantages
– More over different types of simulation such as leakage in the drum, over
temperature error validation, different fill error validation can be simulated in the
system in very simple steps and verified in précised manner.
Different control in
EE for simulation of
different test
conditions
14 Confidential | ETAS | Whirlpool | 2014-04-14| All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.Advantages
– Automation of Test Case
– With the closed loop setup, full automation of test cases which runs for hours are easily executed
and the test results are studied. Test reports are generated which also ensure that documentations
are in place.
– Integration with Variant Management System
– LCO integrated with ETAS variant management system also ensures that the generic plant
model can be used across different variants only by changing the sensor parameters.
– Changing the generic model parameters such as drum volume, pipe diameters will ensure
that the plant model is ready for the next variant.
15 Confidential | ETAS | Whirlpool | 2014-04-14| All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.Summary
– Having an closed loop HiL system with detailed plant model built in Simulink ease the
validation and improve efficiency.
– With the help of automation, it was able to repeat different test cases at any point of
time with the same artifacts.
– Tweaking of sensor values are now no more an difficulty, as they are now done just
with change values and click of buttons.
– The HiL validation was extended to different products such as
– Dish washer
– Refrigerator
– Food Processor etc…
16 Confidential | ETAS | Whirlpool | 2014-04-14| All rights reserved, also regarding any disposal, exploitation, reproduction, editing,
distribution, as well as in the event of applications for industrial property rights.Thank You
Q&A
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