CN110879588A - Design method of test system combining pure electric three-electric ECU (electronic control Unit) with HIL (high-level integrated Circuit) rack - Google Patents
Design method of test system combining pure electric three-electric ECU (electronic control Unit) with HIL (high-level integrated Circuit) rack Download PDFInfo
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Abstract
The invention discloses a design method of a test system of a pure electric three-electric ECU combined HIL rack, which comprises the following steps: step 1, modeling of a controlled object: step 2, virtually modeling the controller to be tested: step 3, carrying out closed-loop debugging on the virtual controller to be tested and the controlled object thereof: step 4, carrying out semi-physical simulation debugging on the three-power single-real controller of the HIL rack: and 5, cascading three electric controllers HIL (high-level integrated Circuit) racks: and 6, carrying out HIL (hardware-in-the-loop) semi-physical integration debugging on the three-power system. The invention can advance the integrated function test of the real vehicle system to the HIL rack, find the problem related to power in the whole vehicle development process as early as possible and correct and modify the problem in time. The power-related problems discovered by real vehicle tests can be rapidly reproduced through the three-electric HIL test platform in time. In addition, partial danger test contents in real vehicle tests can be carried out on the three-electric HIL test bench, so that the life safety of real vehicle testers is guaranteed.
Description
Technical Field
The invention belongs to the technical field of HIL (hardware in the loop) testing, and particularly relates to a design method of a testing system of a pure electric three-electric ECU (electronic control unit) combined HIL rack.
Background
The HIL test (hardware-in-loop test) is an important verification mode of system integration test in the development of a new energy vehicle control strategy V flow. Besides shortening the development period of the controller and reducing the development cost, the HIL testing link is prior to the real vehicle testing, partial limit working condition testing can be performed by utilizing the hardware in the environment of the test, and the risk in the real vehicle testing can be avoided; meanwhile, the fault mode can be rapidly simulated and reproduced, and the risk and the difficulty of fault injection test on the real vehicle are solved. The method simulates the virtual working environment of the running of the whole vehicle controller by building a test model, observes the output of the controller by changing various different input conditions, and verifies whether the logical relationship is realized according to the expected design requirements. The main working principle is shown in figure 1.
The current HIL test is mostly used to perform functional simulation test and verification of a single controller, such as a controller related to a power domain, a body domain or a chassis domain. For the situation that a plurality of controller systems need to be integrated for function verification, real vehicle tests are mostly carried out on real vehicles. The system integrates the real vehicle test mode, brings great limitations to the implementation of partial dangerous working condition test cases, the quantity of exposed problems, the sufficiency of verification problems and the cost of rectification problems, is not favorable for rapidly reproducing and positioning problems, and is particularly suitable for the dangerous test working conditions of a power domain.
Therefore, a new design method for a test system combining a pure electric three-electric ECU and an HIL bench is needed to be developed.
Disclosure of Invention
The invention aims to provide a design method of a test system of a pure electric three-electric ECU combined HIL rack, which can realize simulation test and verification of functions of a power domain system.
The invention relates to a design method of a test system of a pure electric three-electric ECU combined HIL rack, which comprises the following steps:
step 2, virtually modeling the controller to be tested: establishing a virtual model for each controller of the whole electric control system on the upper computer, wherein the virtual model comprises the following steps: establishing a virtual model for a three-electric vehicle controller, a battery management system controller, a motor controller and controllers of other electric control systems of the vehicle with signal interaction with the three-electric controller;
step 4, performing semi-physical simulation debugging on the three-power single-real controller of the HIL rack: respectively and independently configuring external electrical interfaces of three controllers to be tested of three electricity and an HIL electrical interface on HIL equipment, building an IO interface model and a residual bus network simulation model in an environment model on an upper computer, replacing a corresponding virtual controller in the model with a real controller, carrying out simulation debugging by combining the model and the working principle of the controller, and entering step 5 after the respective debugging is passed;
and 5, cascading three electric controllers HIL (high-level integrated Circuit) racks: an IO interface model and a residual bus network simulation model are built in an environment model on an upper computer, and all 3 three-electric virtual controllers in the model are replaced by real controllers; connecting three-electrical cascade hardware on HIL equipment; configuring a three-electrical cascade project in an upper computer;
Further, connecting the three-electrical cascade hardware on the HIL device includes: the three HIL racks are connected with a cascade power supply wire harness for realizing the overall power supply management; the three HIL controllers realize the coaxial cable connection of clock synchronization; the three HIL controllers realize synchronous board card wire harness connection triggered synchronously; the three controller HIL racks realize the optical fiber cable connection of model data interaction; the three HIL controllers realize cascade wire harness connection of fault injection; the three controllers form communication harness connection of a communication loop; the three HIL controllers are connected with a network switch cable for realizing communication between the lower computer and the upper computer; the lower computer is a real-time processor of the HIL equipment and is used for communicating with the upper computer and downloading the test project and the model configured in the upper computer to the lower computer for operation.
Further, the configuration is carried out to three electric cascade engineering in the host computer, include: loading each lower computer, synchronous configuration, model data interaction board configuration, other IO board configuration, model addition and data association.
Further, the controller of other electric control systems of whole car that have signal interaction with the three electric controllers includes: the vehicle-mounted power steering system comprises a vehicle-mounted charger controller, a direct current converter, an electronic hand brake controller, an electric power steering system and a gateway controller.
The invention has the following advantages: according to the invention, the three large electric controllers of the pure electric vehicle power domain are combined through the HIL rack, so that the rack test of the system function of the power domain of the pure electric vehicle is realized. The design method is characterized in that under the condition that large three-power single controller HIL is debugged and passed, hardware and software configuration cascading is carried out on three controller HIL racks, wherein the hardware cascading mainly comprises clock synchronization, synchronous triggering, model data interconnection, bus data interconnection and power supply synchronization. The software cascade mainly comprises the establishment of an interface model and a residual bus model in software such as MATLAB/simulink of an upper computer and the configuration of cascade board card and data interaction in the software engineering of upper computer test. The design method can lead the integrated function test of the real vehicle system to the HIL rack in advance, find the problem related to power in the whole vehicle development process as early as possible and correct and modify the problem in time. The power-related problems discovered by real vehicle tests can be rapidly reproduced through the three-electric HIL test platform in time. In addition, partial danger test contents in real vehicle tests can be carried out on the three-electric HIL test bench, so that the life safety of real vehicle testers is guaranteed.
Drawings
FIG. 1 is a diagram of the operation of a prior art (single controller HIL test system);
FIG. 2 is a schematic diagram of a test system of the pure electric three-electric ECU combined HIL rack according to the invention;
FIG. 3 is a logic flow diagram of the present invention;
in the figure: 1-an upper computer; 2-a network switch; 3-a whole vehicle controller HIL rack; 4-vehicle control unit; 5-battery management system controller HIL rack; 6-battery management system controller; 7-motor controller HIL rack; 8-motor controller.
Detailed Description
The invention will be further explained with reference to the drawings.
Fig. 2 is a schematic diagram of a test system of a pure electric three-electric ECU combined HIL rack, which includes an upper computer 1, a network switch 2, a vehicle control unit HIL rack 3, a vehicle control unit 4, a battery management system controller HIL rack 5, a battery management system controller 6, a motor controller HIL rack 7 and a motor controller 8, wherein the vehicle control unit 4 is connected with the vehicle control unit HIL rack 3, the battery management system controller 6 is connected with the battery management system controller HIL rack 5, the motor controller 8 is connected with the motor controller HIL rack 7, and the vehicle control unit HIL rack 3, the battery management system controller HIL rack 5 and the motor controller HIL rack 7 are in data communication with the upper computer through the network switch 2 respectively.
As shown in fig. 3, a design method of a test system combining a pure electric three-electric ECU and a HIL bench includes the following steps:
Step 2, virtually modeling the controller to be tested: and (3) establishing a virtual model for a three-electric Vehicle Controller (VCU), a battery management system controller (BMS), a Motor Controller (MCU) and controllers of other electric control systems of the whole vehicle with signal interaction with the three-electric controller by using software such as MATLAB/simulink and the like in the upper computer, and then entering step 3. Wherein, have the controller of other electrical system of whole car of signal interaction with the three electric controllers, include: the vehicle-mounted electric power steering system comprises a vehicle-mounted charger controller (OBC), a direct current converter (DCDC), an electronic hand brake controller (EPB), an electric power steering system (EPS) and a Gateway (GW).
Step 4, performing semi-physical simulation debugging on the three-power single-real controller of the HIL rack: respectively and independently configuring external electrical interfaces of three-electric controller to be tested and an HIL electrical interface on HIL equipment, building an IO interface model and a residual bus network simulation model in an environment model by using software such as MATLAB/simulink and the like in an upper computer, replacing a corresponding virtual controller in the model with a real controller, carrying out simulation debugging by combining the model and the working principle of the controller, and entering step 5 after the respective debugging is passed.
And 5, cascading three electric controllers HIL (high-level integrated Circuit) racks: and (3) in the upper computer, using MATLAB/simulink and other software to build an IO interface model and a residual bus network simulation model in the environment model, and completely replacing 3 three-electrical virtual controllers in the model with real controllers.
Connecting three-electric cascade hardware on the HIL equipment, which mainly comprises: the three HIL (central processing unit) racks of the controllers (namely, the VCU rack and the BMS rack and the MCU rack) are connected by a cascade power supply wire harness for realizing the overall power supply management; the three HIL controllers realize the coaxial cable connection of clock synchronization; the three HIL controllers realize synchronous board card wire harness connection triggered synchronously; the three controller HIL racks realize the optical fiber cable connection of model data interaction; the three HIL controllers realize cascade wire harness connection of fault injection; the three controllers form communication harness connection of a communication loop; the three controller HIL racks are connected with a network switch cable for realizing communication between a lower computer (a real-time processor of the HIL equipment, which can be communicated with an upper computer and download a test project and a model configured in the upper computer to the processor for operation) and the upper computer.
The method is characterized in that test software is used in an upper computer to configure the three-electrical-cascade engineering, and the method mainly comprises the following steps: loading each lower computer, synchronous configuration, model data interaction board configuration, other IO board configuration, model addition and data association.
The invention mainly aims to combine three large electric controllers of a pure electric vehicle power domain through an HIL (high-level intelligence) rack to realize the rack test of the system function of the power domain of the whole vehicle. The design method is characterized in that under the condition that large three-power single controller HIL is debugged and passed, hardware and software configuration cascading is carried out on three controller HIL racks, wherein the hardware cascading mainly comprises clock synchronization, synchronous triggering, model data interconnection, bus data interconnection and power supply synchronization. The software cascade mainly comprises the establishment of an interface model and a residual bus model in software such as MATLAB/simulink of an upper computer and the configuration of cascade board card and data interaction in the software engineering of upper computer test. The design method can lead the integrated function test of the real vehicle system to the HIL rack in advance, find the problem related to power in the whole vehicle development process as early as possible and correct and modify the problem in time. The power-related problems discovered by real vehicle tests can be rapidly reproduced through the three-electric HIL test platform in time. In addition, partial danger test contents in real vehicle tests can be carried out on the three-electric HIL test bench, so that the life safety of real vehicle testers is guaranteed.
Claims (4)
1. A design method of a test system combining a pure electric three-electric ECU with a HIL rack is characterized by comprising the following steps:
step 1, modeling of a controlled object: modeling a pure electric vehicle power system and a controlled object model on an upper computer, and the modeling method comprises the following steps: the system comprises a motor model, a battery model, a whole vehicle dynamics model, a reducer model, a chassis system model and a power supply model;
step 2, virtually modeling the controller to be tested: establishing a virtual model for each controller of the whole electric control system on the upper computer, wherein the virtual model comprises the following steps: establishing a virtual model for a three-electric vehicle controller, a battery management system controller, a motor controller and controllers of other electric control systems of the vehicle with signal interaction with the three-electric controller;
step 3, carrying out closed-loop debugging on the virtual controller to be tested and the controlled object thereof: carrying out off-line closed-loop debugging on a single virtual controller and a controlled object model thereof on an upper computer, wherein the off-line closed-loop debugging comprises the following steps: closed-loop debugging of a vehicle controller and a vehicle model, closed-loop debugging of a battery management system controller and a battery model, and closed-loop debugging of a motor controller and a motor model; entering step 4 after the offline closed-loop debugging is passed;
step 4, performing semi-physical simulation debugging on the three-power single-real controller of the HIL rack: respectively and independently configuring external electrical interfaces of three controllers to be tested of three electricity and an HIL electrical interface on HIL equipment, building an IO interface model and a residual bus network simulation model in an environment model on an upper computer, replacing a corresponding virtual controller in the model with a real controller, carrying out simulation debugging by combining the model and the working principle of the controller, and entering step 5 after the respective debugging is passed;
and 5, cascading three electric controllers HIL (high-level integrated Circuit) racks: an IO interface model and a residual bus network simulation model are built in an environment model on an upper computer, and all 3 three-electric virtual controllers in the model are replaced by real controllers; connecting three-electrical cascade hardware on HIL equipment; configuring a three-electrical cascade project in an upper computer;
step 6, three-electric system HIL semi-physical integration debugging: and carrying out HIL cascade debugging on the three-power vehicle controller, the battery management system controller and the motor controller by combining the working principle and the model of each three-power controller, and after the debugging is passed, completing the design of the test system of the pure electric three-power ECU combined with the HIL rack.
2. The design method of the pure electric three-electric ECU combined HIL bench test system according to claim 1, characterized in that: connecting three-electrical cascade hardware on the HIL equipment, comprising: the three HIL racks are connected with a cascade power supply wire harness for realizing the overall power supply management; the three HIL controllers realize the coaxial cable connection of clock synchronization; the three HIL controllers realize synchronous board card wire harness connection triggered synchronously; the three controller HIL racks realize the optical fiber cable connection of model data interaction; the three HIL controllers realize cascade wire harness connection of fault injection; the three controllers form communication harness connection of a communication loop; the three HIL controllers are connected with a network switch cable for realizing communication between the lower computer and the upper computer; the lower computer is a real-time processor of the HIL equipment and is used for communicating with the upper computer and downloading the test project and the model configured in the upper computer to the lower computer for operation.
3. The design method of the pure electric three-electric ECU combined HIL bench test system according to claim 2, is characterized in that: the configuration is carried out to three electric cascade engineering in the host computer, includes: loading each lower computer, synchronous configuration, model data interaction board configuration, other IO board configuration, model addition and data association.
4. The design method of the test system combining the pure electric three-electric ECU and the HIL rack according to any one of claims 1 to 3 is characterized in that: the controller of other electric control systems of whole car that have signal interaction with three electric controllers includes: the vehicle-mounted power steering system comprises a vehicle-mounted charger controller, a direct current converter, an electronic hand brake controller, an electric power steering system and a gateway controller.
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