Hybrid vehicle powertrain test system capable of simulating working condition and inertia

A hybrid vehicle and simulation function technology, applied in vehicle testing, machine/structural component testing, measuring devices, etc., can solve the problem that the working conditions and safety of test personnel are difficult to guarantee, the influence of R&D work level, and the extension of R&D cycle, etc. problems, to achieve the effect of strict control of test conditions, increase of the number of R&D requirements, and elimination of differences in working conditions.

Inactive Publication Date: 2010-06-16
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AI-Extracted Technical Summary

Problems solved by technology

In this way, it is difficult to accurately reproduce the performance of a certain working condition and accurately and completely test the relevant parameters of the system
Coupled with the differences in weather and handling, the handling of road site problems, etc. have great limitations, the improvement of research and development quality is also limited, and the working conditions and safety of test personnel are also difficult to guarantee.
In addition, the im...
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The invention discloses a hybrid vehicle powertrain test system capable of simulating working condition and inertia, which comprises an operating console, a bench control and measuring centre manger, a test mode controlling system unit, a dynamic simulating system unit, a driving function controller unit, a dynamometer, a dynamometer controller unit, a data acquisition system unit and a test condition controlling system unit. The system can be used in the hybrid vehicle powertrain performance development tests; the bench test can replace most of the road tests and the vehicle rotating hub tests in the process of developing the products; meanwhile, assembly parts of the powertrain can be combined flexibly to form different coupling modes of motors and engines to carry out the development and research in the early stage of the development of the hybrid vehicle powertrain; compared with traditional research and development testing means, the test system can greatly improve the hybrid vehicle powertrain and the research and development test level of the key technologies thereof and greatly shorten the research and development period of the powertrain and the relative parts.

Application Domain

Vehicle testing

Technology Topic

DynamometerMode control +13


  • Hybrid vehicle powertrain test system capable of simulating working condition and inertia


  • Experimental program(1)

Example Embodiment

[0015] Such as figure 1 As shown, the bench control and measurement center manager is a comprehensive system to complete the hybrid powertrain bench test. The main components include: operation console, bench control and measurement center manager, test mode control system, dynamic simulation system, Driving function controller, dynamometer and dynamometer controller, data acquisition system, test condition control system, etc.
[0016] The bench control and measurement center manager can perform automatic and manual operations on the bench. The system uses CAN bus to connect all devices, it collects all data and controls all devices.
[0017] The user computer is connected between the bench control and measurement center manager and the vehicle controller HCU of the tested vehicle, which is used to compare and analyze the related data of the bench and the related data of the vehicle HCU in real time, and it is also convenient to compare different HCUs. After “translation” of the communication protocol, it can exchange data with the test bench, keep the vehicle controller HCU of the tested vehicle confidential and make the bench system adapt to the changes of the HCU communication protocol of different vehicle controllers.
[0018] The test bench and the electronic control system of the vehicle under test, such as the vehicle controller HCU and the gearbox controller, have the ability and function of CAN information communication; this can realize the vehicle electronic control system such as vehicle control The information communication between the HCU and the gearbox controller and the bench can use the bench information for vehicle control, or use the vehicle information for bench control, making product development more convenient.
[0019] The bench control and measurement center manager can also be equipped with an emission analyzer interface. Equipped with an emission analyzer system, the bench emission test of the hybrid vehicle power system can also be performed.
[0020] In the steady state test, the dynamometer is the power absorption or power output unit of the power system; in the dynamic simulation test, it is not only the inertia and resistance simulation unit when the vehicle is moving, but also the braking force simulation unit during braking. The dynamometer controller is used to control the bottom layer of the dynamometer, and exchange data with the bench control and measurement center manager through the communication interface, with manual and automatic setting functions.
[0021] The test mode control system defines the test content of the bench test. The control system includes the user-defined closed-loop test for driving cycle simulation developed by the hybrid vehicle, and the user-defined control of the vehicle driving simulation system Simulated open-loop test; also defines the type of gearbox in the power system, such as MT gearbox, AMT gearbox, AT gearbox, etc.; also defines the way to start the engine, such as starter start or drive motor start.
[0022] The closed-loop test is mainly a given test cycle. According to the calculation model, the driving function controller calculates the input value of the pedal and gear based on the actual vehicle speed, the real-time data of the theoretical vehicle speed, and the driving behavior parameters of the driver's demand for speed. It is controlled by the pedal and shift control system. The vehicle controller HCU and the gearbox controller control the vehicle power system according to these input parameters, and complete the test of the entire test cycle. The closed loop test is mainly based on the specified test The research and development of hybrid control strategy is carried out cyclically.
[0023] The open-loop test is mainly to set the pedal and gear input values ​​of the vehicle driving simulation system, and control them through the pedal and gear shift control system. The vehicle controller HCU and the gearbox controller perform adjustments based on these input parameters. The control of the vehicle power system has completed the test test. The open-loop test is mainly to conduct a special test research on the dynamic performance and braking energy feedback performance of the hybrid power.
[0024] The powertrain of the test bench can include actual accelerator pedal, brake pedal, clutch pedal, and shift handle, or virtual pedal and handle.
[0025] The driving function controller is connected to the accelerator pedal actuator and control system, shift actuator and control system, brake pedal actuator and control system, clutch pedal actuator and control system, and driving function controller to form a vehicle driving simulation system. The pedal and shift actuator include a servo motor and a mechanical system that pushes the pedal or shift actuator. The accelerator pedal actuator can use a stepping motor and a ball screw that pushes the accelerator pedal; the shift actuator can use a stepping motor and a ball screw that pushes the shift lever; the brake pedal actuator can use a stepping motor and a push system The ball screw of the moving pedal; the clutch pedal actuator can adopt a stepping motor and a ball screw that pushes the clutch pedal.
[0026] The driving function controller unit may also be a virtual actuator and control system for simulating driving operations without physical entities. The driving function controller unit may also be directly controlled by the driver of the pedal and shift handle.
[0027] The driving function controller can choose to simulate the driving behavior of drivers with different driving habits. According to the target speed and the different reflections of the driver’s speed requirements, the driver model calculates the current pedal position and gear selection, and then passes The driving function control model transmits the calculated target pedal position and target gear to the pedal control system and the gearbox shift control system, through which the pedal and gearbox are controlled to simulate actual driver actions and operating behaviors . The control and collected data of the driving function system can also be transmitted to the user's computer and the vehicle controller HCU in real time. The vehicle controller HCU collects the pedal and gear information of the vehicle power system, realizes the control of the vehicle power system, and completes driving simulation and working condition control.
[0028] Each system also feeds back its own execution status (position signal) to the driving function controller in real time for the next action position calculation. Through the control of the driving function controller and the control of the vehicle controller HCU on the hybrid vehicle power system, the bench can simulate the vehicle starting, acceleration, constant speed, deceleration, coasting, braking and other driving conditions of different driving habits.
[0029] The pedal signal used by the hybrid electric vehicle powertrain test system can be derived from physical hardware or analog electrical signals; the pedal actuator can be a pedal actuator that drives a physical pedal or a virtual pedal. Analog signal actuator. When there is no physical hardware of the hybrid vehicle pedal and gear sensor, the HCU can borrow the pedal signal from the bench system through the user's computer to realize the research on the power distribution, shift strategy and braking energy feedback of the vehicle power system. This method plays a significant role in the pilot development of hybrid products.
[0030] Before the test starts, different test modes can be selected through the test mode control system, such as: 1) open loop test and closed loop test; 2) gearbox type: MT, semi-AMT, AMT, AT, etc.; 3) way to start the engine: start The motor starts the engine, and the motor starts the engine. Different test modes determine different operation actions in the driver model.
[0031] The dynamic simulation system is composed of computer hardware and simulation software. According to the principles of automobile dynamics, use the set vehicle mass, rotational inertia of each component, road rolling resistance coefficient, windward area and drag coefficient of the vehicle, ramp coefficient, relative wind speed, gearbox and main reducer speed ratio, and tire diameter According to the vehicle speed and the torque measured by the dynamometer, the rolling resistance, air resistance, slope resistance, acceleration resistance and braking force are calculated in real time according to the real-time collected vehicle speed and torque measured by the dynamometer. The theoretical torque that should be applied at the dynamometer side is calculated and the value is transmitted to the dynamometer controller in real time to control the output working state of the dynamometer to complete the dynamic simulation of the hybrid vehicle.
[0032] The data acquisition system is equipped with corresponding sensors, measuring instruments, interface modules, analog-to-digital conversion modules, data acquisition software, etc., which convert input signals into digital signals and send them to the management center through the CAN bus. The measurement parameters include temperature, pressure, speed, Traditional engine test bench measurement and control parameters such as torque and fuel consumption also include emissions data, vehicle driving parameters, electrical energy storage and consumption of working components such as voltage, current and electrical energy, and electrical power. It includes multiple torque meters to measure the torque and speed of motors and gearboxes. Among them, high-precision speed sensors can be used to detect the speed of engines, motors, etc. in real time, and angular acceleration sensors and vibration sensors can be used to test the smoothness of shifting and operating conditions. And the emission analyzer interface, so that the system and emission analyzer can synchronize measurement data. The parameters specially required by this bench are: ① Vehicle driving parameters: vehicle speed, travel distance, time, acceleration (deceleration) speed, braking distance, accumulated mileage, pedal force·stroke·time, shift force characteristic curve, etc.; ② Motor and battery working parameters: the current, voltage, electric power, etc. of the power battery (the battery can be a power battery for the vehicle under test or an analog battery) measured by an electric meter.
[0033] The test condition control system receives the given value from the bench control and measurement center manager, and controls the temperature and pressure of engine coolant, fuel, gearbox cooling oil, test room environment and engine intake.
[0034] The test condition control system is mainly used to control the engine coolant temperature, fuel temperature, and engine intake temperature. The test condition control system unit includes engine coolant temperature control system, fuel temperature control system, gearbox temperature control system, environment and engine intake parameter control system. There are two sets of devices in the test condition control system, one is a heating device (directly heating the target), and the other is a cooling device (using another kind of coolant to cool the target). When the system receives the given value from the central manager, Compare with the current measured value to determine the heating device or cooling device to work; when the measured value is close to the target value, use PID to adjust the heating power of the heating device or the flow of coolant in the cooling device to meet the target requirements.
[0035] In a running test, you can set different rolling resistance coefficients, relative wind speeds, slopes and other road condition parameters; you can set the vehicle mass, tire radius, windward area, and non-existent parts on the simulation bench, including wheels and half shafts. , Differential, transmission shaft and other components of the rotational inertia; can set the starting point and end point of the vehicle starting, acceleration, uniform speed, coasting, deceleration, braking, parking and other driving conditions; temperature, pressure, Control parameters for test conditions such as humidity; the measurement parameters that need to be collected can be set. All parameter setting, display, recording, etc. are carried out on the operation console.
[0036] The hybrid electric vehicle powertrain test system can be equipped with a second dynamometer interface. The dynamometer can absorb the output power of the transfer case or the electric motor to achieve functional expansion, making the hybrid powertrain test bench suitable for four Test of the power system of a wheel drive hybrid electric vehicle.
[0037] The hybrid electric vehicle powertrain test system can not only complete all the tests that can be carried out by the traditional engine performance test bench, but also complete the hybrid without the need for the vehicle to carry the platform, the vehicle on the road and the vehicle hub test The following tests of power vehicles:
[0038] · Joint debugging of vehicle controller HCU, AMT controller TCU, engine controller ECU, motor and its controller MCU, battery and management system, and complete the optimization test of the comprehensive performance matching of the hybrid powertrain;
[0039] ·Research and development test of vehicle control strategy (energy distribution);
[0040] ·Brake energy feedback test;
[0041] ·Complete vehicle dynamics simulation test;
[0042] ·Complete vehicle fuel economy simulation test under selected working condition cycles;
[0043] ·Complete vehicle driving simulation test;
[0044] ·Clutch and gearbox shifting smoothness test;
[0045] · Gearbox control strategy development and optimization test;
[0046] ·Development and optimization test of gearbox operating mechanism;
[0047] · Motor performance test;
[0048] ·Hybrid electric vehicle simulation design rapid verification test;
[0049] ·Simulate vehicle emission analysis test;
[0050] ·After the function is expanded, complete the above-mentioned test of the four-wheel drive hybrid electric vehicle.
[0051] The following is an example of using this test system to conduct comprehensive performance test and matching optimization test of hybrid electric vehicle powertrain:
[0052] Build a hybrid electric vehicle power system test system, install the powertrain, and connect test instruments and wiring;
[0053] Enter the vehicle parameters required for the operation of the hybrid vehicle in the dynamic simulation system, such as the quality of the vehicle, the rotational inertia of each component, the road rolling resistance coefficient, the windward area and the wind resistance coefficient, the ramp coefficient, the relative wind speed, the gearbox and the main engine. Data of reducer ratio, tire diameter and other data;
[0054] Select the test mode and test cycle data file in the test mode control system;
[0055] Set the driving intention parameters required by the driver model in the driving function controller, such as soft driving behavior parameters and rough driving behavior parameters;
[0056] Set the working mode of the vehicle controller, whether the platform information collected by the user's computer is used as the control input variable of the HCU, or the HCU directly collects the real driver information as the control input variable of the HCU;
[0057] Enter the control conditions in the test condition control system: test environment temperature, cooling water temperature, fuel temperature, fuel pressure and other data;
[0058] Bench cycle pre-operation debugging;
[0059] Start the formal test;
[0060] Use the test mode control system to select test items and content; use the dynamic simulation system to simulate the dynamic inertia of the hybrid power system using vehicle parameters; use the driving function controller to calculate the pedal and shift actuator according to the input parameters of the driver model Use the actuator to achieve physical control of the signal; use the test condition control system to control the environmental conditions of the hybrid electric vehicle powertrain system according to the input environmental control conditions; use the bench control and measurement center manager to control the bench The data in the test is exchanged and stored to realize test control;
[0061] Use a high-precision speed sensor to measure the engine speed; use a fuel consumption meter to measure the fuel consumption of the engine; use an electric power meter to measure the energy change of the battery; use the torque meter on the dynamometer to measure the output torque and output shaft speed of the powertrain; use The other torque meter measures the torque and speed of the electric assist and energy feedback of the hybrid power system; uses temperature and pressure sensors to measure the temperature and pressure of the parts to be measured;
[0062] Use the data collected by the data acquisition system to analyze and evaluate the control strategy of hybrid power: including energy distribution strategy, driver intention strategy, battery SOC balance strategy, braking energy feedback strategy, etc.;
[0063] Optimize and improve the hybrid vehicle control strategy, repeat the same test, analysis, optimization, and improvement process until a more ideal control strategy for fuel economy, exhaust emissions, ride comfort and power is obtained.


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