Engine Sensor Simulation Card

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The CP-ENG-SIM Engine Sensor Simulation PCIe Card is an FPGA-based I/O solution designed for real-time simulation of engine and vehicle sensor signals. Built for Hardware-in-the-Loop (HIL) environments, the card enables accurate emulation of crank, cam, ignition, fuel injection, and other sensor signals used in engine control systems.

Integrated within Concurrent Real-Time iHawk systems running RedHawk Linux, the card supports deterministic signal generation and acquisition, allowing engineers to validate ECU behavior under controlled, repeatable conditions.

Comprehensive Engine Signal Simulation

The card supports generation and acquisition of key engine-related signals, including:

• Crank angle sensor outputs
• Cam angle sensor outputs
• Ignition signal inputs
• Fuel injection signal inputs
• Wheel speed sensor outputs
• Knock sensor outputs

This allows full interaction with ECU systems by replicating real-world sensor behavior within a simulated environment.

High-Resolution Signal Generation

The system provides precise crank-angle-based signal generation, including:

• Arbitrary pulse pattern configuration
• Resolution of less than 0.006° crank angle at 3,000 RPM
• Waveform generation tied to crank reverse rotation
• Multi-level voltage outputs
• Pulse frequency modulation output

Support for up to four shafts allows simulation of more complex mechanical systems.

Signal Acquisition and Timing Analysis

The card supports acquisition and timing measurement for engine control signals, including:

• Up to 16 ignition signal inputs
• Up to 16 fuel injection signal inputs
• Leading and trailing edge timing capture
• Minimum pulse width of 50 nanoseconds
• Buffered pulse handling

This enables detailed analysis of ECU-generated signals within real-time test environments.

Flexible Digital and Analog I/O

The CP-ENG-SIM includes a combination of digital and analog I/O capabilities:

• 96-channel digital I/O (5V TTL, 3.3V available)
• 16-channel 16-bit digital-to-analog outputs
• 16-channel 16-bit analog inputs

Analog outputs support selectable ranges of 0 to +10V, ±5V, or ±10V, while analog inputs support ±5V or ±10V ranges, enabling integration with a variety of signal types.

Deterministic FPGA-Based Architecture

Built on an Altera Arria V FPGA, the card provides deterministic performance required for real-time simulation. The architecture supports:

• Custom FPGA module integration
• Encoder/decoder functionality
• PWM and SENT signal handling
• High-speed digital isolation

Multi-board synchronization is supported via RJ-style connectors, allowing expansion of channel counts across systems.

High-Speed Data Conversion and Throughput

The system supports:

• Up to 100K updates per second per channel for analog outputs
• Up to 300K updates per second per channel for analog inputs

This enables accurate real-time interaction between simulated signals and ECU responses.

System Integration and Software Support

The card operates within Concurrent’s real-time ecosystem, supporting:

• SIMulation Workbench (SimWB) for configuration and execution
• RedHawk Linux drivers for FPGA-based I/O
• I/O configuration independent of modeling tools

This allows engineers to integrate the card into existing simulation workflows without modifying model structures.

Hardware and System Design

The CP-ENG-SIM is implemented as a PCIe x4 full-length, full-height card and includes:

• Isolated power on all I/O
• 68-pin SCSI connectors for I/O
• RJ-45 connectors for multi-board synchronization
• Onboard clocking with programmable outputs

Optional NIST traceable calibration is available.

Applications

This card is designed for real-time automotive and control system environments, including:

• Engine control unit (ECU) testing
• Hardware-in-the-Loop (HIL) simulation
• Powertrain and drivetrain modeling
• Sensor signal emulation and validation

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