ES830 – Revving Up the Power of Rapid Prototyping

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Not fast enough? Not enough memory? No SSD?
Forget these restrictions from the past!

With the new ES830 high-performance rapid prototyping module, prototyping will never be same! The ES830 is based on an i5processor from Intel and comes with enough power to integrate even enhanced model algorithms. It does this without constraining the capability of rapid prototyping ECU functions, plus it measures and calibrates on the ECU, all at the same time. 

Complete Tool Chain with ETAS Software Products

ETAS software products allow quick and smooth integration. ETAS EHOOKS is the software for the efficient insertion of bypass hooks into compiled ECU software. ETAS INTECRIO, the software for prototyping new ECU functions, brings ECU interface and prototyping software together. Models from ETAS ASCET-DEVELOPER, our model-based development tool for ECU application software, or models from Simulink® can be used directly in INTECRIO –there is no need to manually translate models into C-code. INTECRIO builds executable code for the ES830. All this can be run standalone from flash or interactively, where the functionality of both ECU and prototype on the ES830 can be verified and validated simultaneously with the Measurement and Calibration tool ETAS INCA. Pretty cool, right? Here’s the entire tool chain again in picture form:

ETAS Rapid Prototyping Tool Chain

ETAS Bypass System Faster than Ever

The ES830 is the high-performance external bypass rapid prototyping solution. Bypass rasters < 1 ms with low jitters are possible. Several bus connections are available and you can simultaneously interface to multiple ECUs. This will be of interest especially for the upcoming microprocessor ECUs, such as domain and vehicle controllers and ECUs for ADAS and autonomous driving. Furthermore, due to the early validation and confirmation of the modeled software functions, development quality is increased and the development time, as well as the costs, are reduced. And who doesn’t like time and cost reductions?

Integrating Physical Models

In addition to this classic bypass approach, the calculation power of the ES830-based system lets you use models of the system under test, which are usually computed on large-scale, expensive Hardware-in-the-Loop (HiL) racks.

Also, the smaller size (definitely smaller than your typical HiL rack) and the fact that it is easy to integrate with standard measurement modules, lets you combine the real-time behavior of a physical ECU network in an actual car with virtual physical conditions. And these virtual conditions can be accurately and reliably created and easily repeated with a modeling system – for instance with ETAS ASCMO, Mathwork’s Matlab®/Simulink® or Gamma Technology’s GT-Suite.

Example: Run an ETAS ASCMO NOx Emission Model on the ES830

Let’s take a closer look at an example where we use an ASCMO model to get a virtual sensor for NOx emissions. This approach is commonly used in today’s virtual calibration of ECUs.

Direct injected gasoline engine with varied inputs and the NOx emission output to be modeled

A Design of Experiment (DoE) with 800 input parameter variations was used to collect a representative data set from the engine dynamometer. From this, the Gaussian process is able to create a very accurate model. The number of variations can be further compressed to M=100 without significantly decreasing the model quality. A model like this, generated with ASCMO, executes fast enough to realize the virtual sensor in a fraction of a microsecond on an ES830.

Rapid prototyping with ASCMO, INTECRIO and ES830 and ES891 hardware


In a nutshell, rapid prototyping projects, which were just not doable in the past, are now technically feasible. The immense calculation power of the ES830 rapid prototyping module together with an ES891 interface module make it all possible.

If you have any questions about anything in this post or a specific project you’re working on, just comment below or contact us!