Engine test verification system and method based on virtual rack

Abstract

The invention provides an engine test verification system and method based on a virtual rack, and belongs to the field of engine testing. A control upper computer is used for acquiring a control instruction, controlling the virtual rack to start, setting the input quantity and initial test conditions of the virtual rack, and receiving data fed back by the virtual rack in the running state of the virtual rack; the test upper computer is used for calibrating test parameters of the ECU and receiving, displaying and storing real-time data of the ECU when a test is executed; the ECU receives the control quantity of the actuator fed back by the virtual rack and the test parameters sensed by the sensor, compares the control quantity and the test parameters with a target value required by the engine under the current test working condition, and controls the control quantity of the actuator of the virtual rack through a closed loop; according to the invention, the simulation of the engine is carried out by using the virtual rack, the test of the engine on the real rack is effectively replaced, and the flexibility and convenience of the test are improved.

Description

Technical Field

[0001] The invention belongs to the field of engine testing, and in particular relates to an engine testing verification system and method based on a virtual bench. Background Art

[0002] As the engine is updated and iterated faster and faster. The engine is a complex system, a highly integrated collection of mechanical, electronic, control, emission and other technologies. It is necessary to ensure the precision of each part, which is inseparable from the engine testing and verification. At present, the mainstream and most widely used engine testing and verification method is the engine bench test, which mainly includes engine performance function reliability test verification, engine emission test, engine or component life durability test, etc.

[0003] In the prior art, due to the large size of the engine and the inconvenience of installation, the workload is acceptable when conducting endurance tests because there is no need to frequently replace engine parts. However, when conducting engine performance function tests and emission tests, the time spent on disassembling and assembling the engine, replacing parts and other preparatory work will be greatly increased. And when there is a need to temporarily test a single new function, whether the existing test is shut down or an empty test bench is occupied, the entire test bench will be occupied, resulting in low test bench utilization. At the same time, using a real test bench to test the engine requires a considerable amount of oil as a driving medium, which causes material consumption during the test process. How to use a virtual test bench to replace the real engine can achieve equivalent replacement for some pre-emptive, temporary, repetitive, and functional verification tests, as well as testing and calibration of repetitive working conditions of the engine ECU, and alleviate the pressure on the real engine test bench is a technical problem that needs to be solved urgently. Summary of the invention

[0004] The present invention provides an engine test verification system based on a virtual test bench, which utilizes the virtual test bench to simulate the engine to test and verify the performance function of the engine, effectively replacing the experimental test of the engine on the real test bench, saving manpower, material resources and time costs, and improving the flexibility and convenience of the test.

[0005] The system includes: control host computer, test host computer, ECU electronic control unit and virtual test bench;

[0006] The control host computer is connected to the virtual test bench in communication. The control host computer is used to obtain control instructions, control the start of the virtual test bench, set the input quantity and initial test conditions of the virtual test bench, and receive data fed back by the virtual test bench when the virtual test bench is in operation;

[0007] The test host computer is connected to the ECU electronic control unit in communication. The test host computer is used to calibrate the test parameters of the ECU electronic control unit. When executing the test, it receives, displays and saves the real-time data of the ECU electronic control unit.

[0008] The ECU electronic control unit is connected to the virtual test bench in communication. The ECU electronic control unit is used to receive the control quantity of the actuator and the test parameters sensed by the sensor fed back by the virtual test bench, compare them with the target value required by the engine under the current test conditions, and control the control quantity of the virtual test bench actuator through a closed loop;

[0009] The virtual test bench is used to receive the start control command, input quantity, test initial conditions and control quantity sent by the control host computer and respond, and also feed back the test data to the control host computer, and feed back the control quantity of the actuator and the test parameters sensed by the sensor to the ECU.

[0010] It should be further explained that the control host computer includes: PUMA software platform;

[0011] The PUMA software platform is connected to the virtual test bench for communication. The PUMA software platform configures the engine operation information and operation time of each operating point, formulates the engine operating condition control table, issues control instructions to the engine, controls the engine operation in real time, and receives and stores the real-time operation data of the engine model.

[0012] It should be further explained that the control host computer also includes: a strategy control platform;

[0013] The strategy control platform is configured with multiple channels, defines the function of each channel and the execution order of multiple channels, regulates the input quantity of the virtual test bench based on multiple channels, sets the signal status of each input quantity of the virtual test bench, and switches the channels of each input signal of the virtual test bench.

[0014] It should be further explained that the test host computer includes: ETAS software platform;

[0015] The ETAS software platform exchanges calibration data with the ECU electronic control unit in real time to configure the engine's performance parameters and emission characteristics;

[0016] The user configures the measurement parameters of the ETAS device based on the ETAS software platform and records the output parameters and sensor signals of the ECU electronic control unit;

[0017] Based on the ETAS software platform, users obtain various parameters of engine operation, compare and analyze them with the engine bench calibration values ​​to find out the differences, and adjust the different parameters within the preset limit range. At the same time, the ETAS software platform monitors and records the fault codes and error status of the ECU electronic control unit.

[0018] It should be further explained that the test host computer also includes: CAN tool software platform.

[0019] The CAN tool software platform receives messages sent by the ECU electronic control unit through the J1939 protocol to determine the operating status of the engine simulated by the virtual test bench.

[0020] It should be further explained that the ECU electronic control unit is connected to the ETAS software platform through the ETAS calibration equipment, and is connected to the CAN tool software platform through the CAN bus tool;

[0021] The ECU electronic control unit determines the state of the engine by reading the sensor signals and engine status quantities of the virtual test bench, and feeds back the engine status information to the test host computer; at the same time, it receives the calibration signals and control CAN messages sent by the test host computer, intervenes in the engine state simulated by the virtual test bench, and realizes closed-loop control of the measurement signal.

[0022] It should be further explained that the ECU electronic control unit controls the working state of the engine by controlling the operation of the engine's ignition coil, injector, and throttle actuator.

[0023] It should be further explained that the virtual test bench includes a real-time machine, which carries an engine model and a post-processing model;

[0024] The engine model and post-processing model collect bench test steady-state parameters and transient test data respectively to ensure that the simulation output parameters and bench test data are within the error range;

[0025] The engine model is connected to the post-processing model in communication. The engine model sends an upstream emission data signal to the post-processing model according to the received signal. The post-processing model calculates and feeds back the downstream emission data and then sends it to the engine model.

[0026] It should be further explained that the virtual test bench is connected to the control host computer, the test host computer, and the ECU electronic control unit through the hardware communication port;

[0027] The hardware communication ports include: IO interface, Ethernet interface and CAN bus interface.

[0028] According to another embodiment of the present application, a virtual bench-based engine test verification method is provided.

[0029] Methods include:

[0030] The control host computer obtains control instructions and controls the virtual test bench to start. The virtual test bench receives the start control instructions, input quantities, test initial conditions and control quantities sent by the ECU electronic control unit sent by the control host computer, responds, and also feeds back test data to the control host computer, and feeds back the control quantities of the actuators and the test parameters sensed by the sensors to the ECU electronic control unit;

[0031] The host computer is used to test the test parameters of the ECU electronic control unit. When executing the test, the real-time data of the ECU electronic control unit is received, displayed and saved;

[0032] The ECU electronic control unit receives the control quantity of the actuator fed back by the virtual test bench and the test parameters sensed by the sensor, compares them with the target value required by the engine under the current test conditions, and controls the control quantity of the virtual test bench actuator through a closed loop.

[0033] It can be seen from the above technical solutions that the present invention has the following advantages:

[0034] In the engine test verification system and method based on a virtual test bench involved in the present application, by using a virtual test bench instead of an actual physical test bench for testing, the hardware cost required for testing is reduced, including the cost of purchasing, maintaining, updating, and energy consumption of physical equipment. The virtual test bench of the present application can quickly simulate various test conditions and conditions without the need for complex settings and adjustments like a physical test bench, shortening the test cycle and improving test efficiency. The virtual test bench can also easily adjust test parameters and conditions, allowing test engineers to flexibly design a variety of test plans to meet different test requirements.

[0035] This application is tested in a virtual environment, which can avoid safety accidents caused by improper testing or equipment failure, and ensure the safety of testers and equipment. The virtual test bench provides strong support for the development and optimization of engine control systems. Through repeated testing and verification, control algorithms and parameters can be continuously optimized to improve engine performance and reliability.

[0036] The test host computer can receive and save the real-time data of the ECU electronic control unit in real time, providing data support for subsequent data analysis and optimization. It can be used to evaluate engine performance, identify potential problems, and guide subsequent R&D work.

[0037] The ECU electronic control unit receives the actuator control quantity and sensor test parameters fed back by the virtual test bench and compares them with the target value to achieve closed-loop control. It can more accurately adjust the engine operating state and improve the accuracy and reliability of the test. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the technical solution of the present invention, the accompanying drawings required for use in the description will be briefly introduced below. Obviously, the accompanying drawings in the following description are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative work.

[0039] Figure 1 The schematic diagram of the engine test verification system based on the virtual bench;

[0040] Figure 2 It is a schematic diagram of an embodiment of an engine test verification system based on a virtual bench. DETAILED DESCRIPTION

[0041] The engine test verification system based on the virtual bench provided by the present application includes a control host computer, a test host computer, an ECU electronic control unit and a virtual bench. Of course, for the purpose of illustration rather than limitation, specific details such as specific system structures and technologies are proposed so as to thoroughly understand the embodiments of the present application. However, it should be clear to those skilled in the art that the present application can also be implemented in other embodiments without these specific details.

[0042] It should be understood that when used in the present specification, the term "includes" indicates the presence of the described features, integral bodies, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integral bodies, steps, operations, elements, components and / or their collections. The terms "include", "comprise", "have" and their variations all mean "including but not limited to", unless otherwise specifically emphasized.

[0043] It should be understood that the "one or more" mentioned in this application refers to one, two or more than two, and the "multiple" mentioned in this application refers to two or more. In the description of this application, unless otherwise specified, " / " means or, for example, A / B can mean A or B. The "and / or" in this article is just a way to describe the association relationship of associated objects, indicating that there can be three relationships. For example, A and / or B can mean: A exists alone, A and B exist at the same time, and B exists alone.

[0044] The phrases such as "one embodiment" or "some embodiments" described in the present application mean that the specific features, structures or characteristics described in the embodiment are included in one or more embodiments of the present application. Therefore, the phrases such as "in one embodiment", "in some embodiments", "in some other embodiments", "in some other embodiments" etc. that appear in different places in the present application do not necessarily refer to the same embodiment, but mean "one or more but not all embodiments", unless otherwise specifically emphasized in other ways.

[0045] The control host computer and the test host computer involved in the present application can be implemented in various forms. For example, the terminal described in the embodiment of the present invention may include a mobile terminal such as a mobile phone, a notebook computer, a personal digital assistant (PDA, Personal Digital Assistant), a tablet computer (PAD), etc. and a fixed terminal such as a digital TV, a desktop computer, etc. However, it will be understood by those skilled in the art that, in addition to the elements specifically used for mobile purposes, the construction according to the embodiment of the present invention can also be applied to a fixed type terminal.

[0046] The control host computer and the test host computer may also include network equipment and / or user equipment. The network equipment includes, but is not limited to, a single network server, a server group consisting of multiple network servers, or a cloud consisting of a large number of hosts or network servers based on cloud computing.

[0047] The network where the control host computer and the test host computer are located includes but is not limited to the Internet, wide area network, metropolitan area network, local area network, virtual private network (VPN), etc.

[0048] The ECU electronic control unit in this application stands for Electronic Control Unit, which is a vehicle computer.

[0049] The ECU electronic control unit includes: a microprocessor, memory (ROM, RAM), input / output interface, analog-to-digital converter and integrated circuit. The ECU electronic control unit can calculate, process and judge the information input by the air flow meter and various sensors, and then output instructions. Provide electrical pulse signals to the injector to control the injection amount, thereby achieving precise control of the engine and other systems. In turn, it can meet the engine test verification requirements of this application.

[0050] The virtual test bench of the present application is used to simulate a real engine and after-treatment system, send the system real-time emission data and status quantity to the control host computer; receive the experimental initial condition signal and the control quantity of the ECU electronic control unit from the control host computer, respond in real time and calculate to generate feedback data, and send the real-time feedback data to the ECU electronic control unit.

[0051] The engine test verification system based on the virtual bench of the present application can acquire and process the associated engine data based on the control host computer, the test host computer, the ECU electronic control unit and the virtual bench. The theory, method, technology and application device of using the machine simulation of digital computers, extending and expanding human intelligence, sensing the environment, acquiring engine data and using engine data to obtain the best results. It also realizes the simulation test of the engine by establishing the communication relationship between the control host computer, the test host computer, the ECU electronic control unit and the virtual bench, and using sensor monitoring, data transmission and other technologies, thereby reflecting the operating status of the engine under different working conditions, realizing the test and calibration of the repetitive working conditions of the engine ECU to achieve equivalent substitution, alleviating the pressure of the real engine bench, and saving economic and time costs.

[0052] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0053] See also Figure 1 As shown, the engine test verification system based on the virtual bench of this embodiment includes: a control host computer, a test host computer, an ECU electronic control unit and a virtual bench.

[0054] The control host computer is connected to the virtual test bench in communication. The control host computer is used to obtain control instructions, control the startup of the virtual test bench, set the input quantity and initial test conditions of the virtual test bench, and receive data fed back by the virtual test bench when the virtual test bench is in operation.

[0055] The test host computer is connected to the ECU electronic control unit for communication. The test host computer is used to calibrate the test parameters of the ECU electronic control unit and receive, display and save the real-time data of the ECU electronic control unit when executing the test.

[0056] According to an embodiment of the present application, the test host computer receives and monitors real-time data of the ECU electronic control unit, calibrates and optimizes test parameters of the ECU electronic control unit, and interacts with the ECU electronic control unit in sending and receiving CAN communication messages.

[0057] The test host computer of this embodiment reads various parameters of the engine in the ECU electronic control unit through the ETAS software platform or CAN device, compares and analyzes the read parameters with the engine bench calibration values ​​to find out the differences, and continuously optimizes and adjusts the parameter control calibration quantities with differences within the preset limit ranges, so that the engine parameters finally meet the requirements, generates a DCM file with the adjusted parameters, imports it into the engine P file, and performs engine bench verification.

[0058] For example, this embodiment uses the calibration function of the ETAS software platform to accurately calibrate and optimize the automotive ECU. It also supports the adjustment of various calibration parameters, such as fuel injection, ignition timing, sensor calibration, etc. It also supports online calibration, which can monitor and adjust ECU parameters in real time to meet the test requirements of the engine.

[0059] In some embodiments, the ECU electronic control unit is connected to the virtual test bench in communication, and the ECU electronic control unit is used to receive the control amount of the actuator and the test parameters sensed by the sensor fed back by the virtual test bench, compare them with the target value required by the engine under the current test condition, and control the control amount of the virtual test bench actuator through closed loop control. It can be seen that the ECU electronic control unit receives the actual measured parameters of various actuators and sensors fed back by the virtual test bench under the current working condition, and then compares them with the target value required by the engine under the working condition, and increases or decreases the control amount of the target actuator or sensor through closed loop control.

[0060] According to an embodiment of the present application, the virtual test bench is used to receive the startup control instructions, input quantities, test initial conditions and control quantities sent by the control host computer and respond, and also feed back the test data to the control host computer, and feed back the control quantity of the actuator and the test parameters sensed by the sensor to the ECU electronic control unit.

[0061] The system involved in this embodiment uses a virtual test bench to simulate the engine to test and verify the performance functions of the engine, which effectively replaces the experimental test of the engine on the real test bench, saves manpower, material resources and time costs, and improves the flexibility and convenience of the test.

[0062] On the basis of the above embodiments, in order to further improve the reliability of the engine test verification system provided by the above embodiments, as an implementable method, a possible embodiment will be given below to illustrate its specific implementation scheme in a non-limiting manner.

[0063] In an exemplary embodiment, the host computer controls the startup of the virtual test bench according to the control instructions input by the tester, then calls up the settings of the virtual test bench input quantity, transmits the setting results and the initial conditions of the test to the virtual test bench, and simultaneously receives the emission data and engine status quantity fed back by the virtual test bench.

[0064] Specifically, the control host computer includes: PUMA software platform and strategy control platform.

[0065] The PUMA software platform is a tool for developing and testing automotive buses. The PUMA software platform communicates with the virtual test bench through the CAN bus, sending the initial temperature and environmental condition parameters to the virtual test bench to complete the initial state setting. It also sends a start signal to control the engine start of the virtual test bench, and controls the engine speed, torque, and throttle opening in real time.

[0066] In some embodiments of the present application, the PUMA software platform can receive sensor data from the real-time operation of the engine model, such as intake temperature / pressure, exhaust temperature / pressure, original exhaust, and tail exhaust, to achieve real-time monitoring and recording of engine temperature / pressure sensor variables and emission data.

[0067] The PUMA software platform can also configure the speed, torque, throttle opening and other information of each operating point as well as the operating time of the operating point, and formulate an engine operating condition control table, which can be imported into the PUMA software platform, or the road spectrum data can be imported to obtain the test cycle operating condition. The PUMA software platform then controls the engine by issuing instructions according to the operating point to realize the engine's automated operating condition.

[0068] In some embodiments of the present application, the strategy control platform is constructed using SIMULINK software, which is used to effectively adjust the input quantity of the virtual test bench, set the signal state of each input quantity of the virtual test bench, and can switch channels for each input signal of the virtual test bench.

[0069] The system of the embodiment of the present application embeds different controlled objects into the data stream. Specifically, the policy control platform of the present embodiment is configured with multiple channels, defines the function of each channel and the execution order of the multiple channels, regulates the input quantity of the virtual test bench based on the multiple channels, sets the signal state of each input quantity of the virtual test bench, and performs channel switching for each input signal of the virtual test bench.

[0070] The specific implementation process is: set up four channels, and then set up a multi-state switch structure to switch the input signal source channel. Among them, channel one is connected to the data input module; channel two imports .mat files or .xlsx files as operating condition tables, and adds a table lookup module to obtain the corresponding time operating conditions; channel three directly sets a single-line steady-state operating point in SIMULINK; channel four directly obtains the real-time calculation amount of the virtual test bench through the CAN communication channel, and uses the virtual test bench's own closed-loop control to achieve complete self-control.

[0071] During the test, different signal sources are selected on the software page, so that the input interface of each input quantity can be manually input with fixed values ​​in channel 1. Channel 2 switches between variable working conditions set in advance, channel 3 preset steady-state working conditions, and channel 4 switches between internal autonomous calculation values ​​based on the virtual bench. During the experiment, the signal channel of the selected variable is switched in real time, so as to realize fault injection during working condition operation or complete working conditions under certain specific conditions, and further complete the engine performance function test.

[0072] In some embodiments, the test host computer receives and monitors real-time data of the ECU electronic control unit, calibrates and optimizes test parameters of the ECU electronic control unit, and performs CAN communication message transmission and reception interaction with the ECU electronic control unit.

[0073] In some specific embodiments, the test host computer includes: an ETAS software platform and a CAN tool software platform.

[0074] Among them, the ETAS software platform is the ETAS (Engineering Tools, Application, and Services) software platform, which can realize the simulation, debugging, measurement and calibration of automotive electronic systems.

[0075] The ETAS software platform of this application can integrate simulation environment, support multi-domain simulation and joint simulation, and help testers verify and test complex automotive electronic systems in a virtual environment. It also extends the simulation software to the cloud, provides AI-generated simulation driving scenario input, supports large-scale parallel computing and customized test report output.

[0076] It should be noted that the ETAS software platform provides measurement, data acquisition, calibration and diagnostic functions. Based on the ETAS software platform, testers can measure and record the output of the ECU electronic control unit and the signals of various sensors by selecting and configuring ETAS equipment.

[0077] Here, the operating state of the system can be changed by adjusting the parameters in the ECU electronic control unit, obtaining real-time data, modifying parameters and reloading calibration data, and by communicating with the ECU electronic control unit, updating parameters in real time and providing instant feedback information.

[0078] The tester of this embodiment uses the various parameters of the engine in the ETAS software platform to compare and analyze the read parameters with the engine bench calibration values ​​to find out the differences, and continuously optimizes and adjusts the parameter control calibration quantities with differences within the preset limit values. At the same time, the ETAS software platform can be used to monitor and record the fault codes and error states of the ECU electronic control unit to quickly diagnose and solve relevant problems of the engine in the test, and finally make the engine parameters meet the requirements, generate a DCM file with the adjusted parameters, import it into the engine P file, and perform engine bench verification, finally helping to effectively manage and optimize the engine system during the engine test verification process.

[0079] The CAN tool software platform of this embodiment is a CAN (Controller Area Network) bus communication platform. It supports multiple communication protocols, including CAN, LIN, and FlexRay, etc. It can provide rich functions such as network simulation, node simulation, data monitoring and analysis, etc.

[0080] As an embodiment of the present application, the CAN tool software platform receives the test message sent by the ECU electronic control unit through the J1939 protocol, determines the operating status of the engine simulated by the virtual test bench, and the tester sets the channel address, definition and message content for the engine to receive or send CAN messages, sets the receiving and sending rates of the receiving and transmitting devices, sets the priority of the CAN message control mode and the normal control mode, and intervenes in the engine speed and torque according to the actual engine operating conditions to meet the actual needs. By monitoring the engine's response and the feedback CAN messages, it is determined that the parameter adjustment is effective, thereby adjusting the engine's operating conditions.

[0081] In an embodiment of the present application, the ECU electronic control unit is used to receive real-time engine data generated by a virtual test bench and calibration optimization signals and CAN messages sent by a test host computer, and calculate corresponding control quantities based on the real-time instructions and send them as feedback to the virtual test bench.

[0082] In a specific embodiment of the present application, the ECU electronic control unit is communicatively connected to the ETAS software platform via an ETAS calibration device, and is communicatively connected to the CAN tool software platform via a CAN bus tool.

[0083] The ECU electronic control unit determines the engine status by reading and monitoring the sensor signals and engine status of the virtual test bench, feeds back the engine status information to the test host computer, receives calibration signals and control CAN messages, intervenes in the engine status simulated by the virtual test bench, and realizes a closed loop of measurement signal control.

[0084] In some embodiments of the present application, the ECU electronic control unit outputs a control signal through connection with the engine control actuator to control the working state of the engine.

[0085] For example, the ECU electronic control unit can control the engine's ignition coil, fuel injector, throttle actuator, etc. The ECU controls the combustion process by adjusting the ignition timing, adjusts the fuel supply by controlling the fuel injection amount, and adjusts the intake volume by controlling the valve opening time.

[0086] In other embodiments, the ECU electronic control unit receives the parameters actually measured by various actuators and sensors fed back by the virtual test bench, compares them with the target values ​​required by the engine under the current operating conditions, increases or decreases the control amount of the target actuator or sensor through closed-loop control, and the target setting value is transmitted and sent through the test host computer in the form of a calibration signal (ECU calibration amount) or a CAN message.

[0087] For the virtual test bench of the present application, the virtual test bench is used to simulate a real engine and post-processing system, and send the real-time emission data and status of the system to the control host computer.

[0088] The virtual test bench receives the experimental initial condition signal from the control host computer and the control quantity of the ECU electronic control unit, responds and calculates to generate feedback data in real time, and sends the real-time feedback data to the ECU electronic control unit.

[0089] In some specific embodiments, the virtual test bench includes: a real-time machine, in which an engine model and a post-processing model are mounted.

[0090] The engine model and post-processing model are built by collecting high-quality bench test steady-state and transient test data to ensure that the simulation output parameters and bench test data are within the error range, making them close to the real engine and post-processing modules.

[0091] Optionally, there is internal data interaction between the engine model and the post-processing model: the engine model sends an upstream emission data signal to the post-processing model based on the received signal, and the post-processing model feeds back downstream emission data to the engine model based on calculation, and judges the rationality of the data according to internal logic to achieve internal self-consistency and ensure the normal operation of the model without crashing.

[0092] It should be noted that the real test bench engine sensor essentially converts the change of physical quantity into electrical signals. The voltage, current and resistance signals in the virtual test bench are generated and measured by the onboard hardware boards. The hardware boards are directly controlled by the engine and post-processing model and can be regarded as part of the real-time machine.

[0093] The virtual test bench of this embodiment communicates with the control host computer, the test host computer, and the ECU electronic control unit respectively through the hardware communication port. The hardware communication port includes an IO interface, an Ethernet interface, and a CAN bus interface, which realizes the two-way transmission of digital signals, analog signals, PWM waveform signals, CAN bus signals, Ethernet signals and other signals, ensures the rate of signal acquisition and data transmission, and realizes the real-time performance of signal transmission.

[0094] The virtual test bench of this embodiment is directly connected to the ECU electronic control unit externally, and the relevant pins of the ECU electronic control unit are connected to the signal hardware boards of the virtual test bench through the hardware communication port. The real-time machine equipped with the engine model and the post-processing model generates an electrical signal of the corresponding frequency according to the needs of the ECU. Under the premise of ensuring the rate of signal acquisition and data transmission, the ECU will not report an error of signal loss due to transmission gaps, thereby realizing the hardware-in-the-loop of the ECU electronic control unit in the entire system.

[0095] For the embodiments of the present application, the engine test bench itself is a complex system, which is a highly integrated body of mechanical, electronic, control and other technologies. The engine model and the post-processing model can provide a visual and digital description of the actual engine test bench.

[0096] The engine model and post-processing model of this embodiment are built using CruiseM software to generate a model standardization model package .fmu file, which is loaded into the real-time machine of the virtual bench. The data signal simulation step of the engine model and the post-processing model matches the signal acquisition and data transmission rate of the ECU electronic control unit to ensure a high degree of consistency between the real-time machine clock and the ECU electronic control unit clock.

[0097] The engine model relies on high-precision experimental data, and the entire model is parameterized according to thermodynamic formulas, mechanical dynamics formulas, etc., so that its accuracy is close to that of the real engine; at the same time, the engine model has extremely high simulation real-time performance, and when the ECU electronic control unit hardware is in the loop, it ensures that the model does not crash and does not report hardware signal loss failures.

[0098] For this embodiment, the engine model includes: a transmission shaft module (crankshaft, camshaft), an ignition injection module, a rail pressure module, a CAN module, etc. Further, it is subdivided into various sensor signals to simulate the transmission and reception of all sensor signals of the engine. Take the injector signal as an example: the hardware board collects and processes the injection waveform of each cylinder injector according to the injection waveform capture principle (threshold, hysteresis, edge condition), and collects and records the parameters of each cylinder injector, such as the cylinder number, injection pulse count, power-on start angle, power-on end angle, and power-on duration.

[0099] Among them, the power-on start angle and the power-on end angle are both relative to the angle of the top dead center of each cylinder. According to the control logic of the ECU electronic control unit, the angle before the top dead center is defined as a positive value, and the angle after the top dead center is defined as a negative value.

[0100] The corresponding threshold boundary and hysteresis data and the edge conditions of the two are input into the engine model, and the capture parameters are provided to the board. The board measures the injection situation based on the captured parameters. In the real engine situation, a continuous injection parameter input is required, so it is necessary to combine and output the signals measured by all the boards in the model to simulate it.

[0101] The fuel injection of each cylinder of the engine in this embodiment is independent of each other, and the fuel is injected and burned in sequence in a certain order. By importing the injection MAP into the table lookup module, the output data records the data of the cylinder currently injecting fuel. When injecting fuel in other cylinders, the output signal immediately changes to the signal of the next cylinder.

[0102] In this way, the injection parameters of each cylinder are integrated into one path output, and the injection parameters are continuously output according to the crankshaft angle. Based on the recorded injection data, the fuel consumption of the engine can be calculated, which has guiding significance for the strategy of reducing fuel consumption. The measurement and recording process of the remaining sensor signals is basically similar, and the overall process relies on high-quality experimental data and thermodynamics / mechanical dynamics formulas, empirical formulas, etc., to ensure that the accuracy of the entire model is close to that of the real engine.

[0103] The post-treatment model in this embodiment includes: particulate filter DPF, oxidation catalyst DOC, selective catalytic reduction DPF, ammonia oxidation catalyst ASC and other modules, which exchange data with each other to form a data stream. Based on high-precision experimental data, gas combustion formula, thermodynamic formula, and empirical formula, the catalytic effect of the oxidation catalyst in the process of oxidizing carbon monoxide (CO) and unburned hydrocarbons (HC) into carbon dioxide (CO2) and water (H2O) is described.

[0104] The urea solution is used to reduce nitrogen oxides (NOx) to nitrogen (N2) and water (H2O) in a catalytic process, and the excess ammonia (NH3) is oxidized to nitrogen (N2), nitrogen dioxide (N2O), and nitrogen oxides (NOx). At the same time, the nitrogen oxides (NOx) and ammonia (NH3) are catalyzed to react into nitrogen (N2). This allows real-time simulation of various pollutants emitted by the engine, including the generation and control strategies of NOx, CO, HC, and particulate matter, and simulation of emission levels under different strategies. Similarly, the post-processing model has a high degree of real-time performance, ensuring the stability of the signal reception of the ECU electronic control unit and avoiding errors caused by the loss of post-processing signals.

[0105] In this way, integrating the engine model with the post-treatment model can effectively evaluate the comprehensive emission performance and fuel economy of the engine under various operating conditions, and provide decision support for engine research and development.

[0106] The engine test and verification system of the present embodiment utilizes a virtual test bench to simulate a real engine, injects faults in real time and flexibly adjusts variables according to R&D test requirements, and can achieve equivalent substitution for some preliminary, temporary, repetitive, and functional verification tests and verifications, as well as testing and calibration of repetitive working conditions of the engine ECU, thereby alleviating the pressure on the real engine test bench and saving economic and time costs.

[0107] The following is an embodiment of an engine test verification method based on a virtual bench provided in an embodiment of the present disclosure. This method and the engine test verification system based on a virtual bench in the above-mentioned embodiments belong to the same inventive concept. For details not fully described in the embodiment of the engine test verification method based on the virtual bench, reference can be made to the above-mentioned embodiment of the engine test verification system based on the virtual bench.

[0108] Methods include:

[0109] The control host computer obtains control instructions and controls the startup of the virtual test bench. The virtual test bench receives the startup control instructions, input quantities, test initial conditions and control quantities sent by the ECU electronic control unit sent by the control host computer, responds, and feeds back test data to the control host computer, and feeds back the control quantities of the actuators and the test parameters sensed by the sensors to the ECU electronic control unit.

[0110] The test host computer calibrates the test parameters of the ECU electronic control unit. When executing the test, it receives, displays and saves the real-time data of the ECU electronic control unit.

[0111] The ECU electronic control unit receives the control quantity of the actuator fed back by the virtual test bench and the test parameters sensed by the sensor, compares them with the target value required by the engine under the current test conditions, and controls the control quantity of the virtual test bench actuator through a closed loop.

[0112] It should be understood that the order of execution of the steps in the above embodiment does not necessarily mean the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiment of the present invention.

[0113] In the engine test verification system and method based on a virtual test bench involved in the present application, by using a virtual test bench instead of an actual physical test bench for testing, the hardware cost required for testing is reduced, including the cost of purchasing, maintaining, updating, and energy consumption of physical equipment. The virtual test bench of the present application can quickly simulate various test conditions and conditions without the need for complex settings and adjustments like a physical test bench, shortening the test cycle and improving test efficiency. The virtual test bench can also easily adjust test parameters and conditions, allowing test engineers to flexibly design a variety of test plans to meet different test requirements.

[0114] This application is tested in a virtual environment, which can avoid safety accidents caused by improper testing or equipment failure, and ensure the safety of testers and equipment. The virtual test bench provides strong support for the development and optimization of engine control systems. Through repeated testing and verification, control algorithms and parameters can be continuously optimized to improve engine performance and reliability.

[0115] The test host computer can receive and save the real-time data of the ECU electronic control unit in real time, providing data support for subsequent data analysis and optimization. It can be used to evaluate engine performance, identify potential problems, and guide subsequent R&D work.

[0116] The ECU electronic control unit receives the actuator control quantity and sensor test parameters fed back by the virtual test bench and compares them with the target value to achieve closed-loop control. It can more accurately adjust the engine operating state and improve the accuracy and reliability of the test.

[0117] The engine test verification system and method based on a virtual bench involved in the present application are the units and algorithm steps of each example described in combination with the embodiments disclosed herein, and can be implemented by electronic hardware, computer software or a combination of the two. In order to clearly illustrate the interchangeability of hardware and software, the composition and steps of each example have been generally described in terms of function in the above description. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professional and technical personnel can use different methods to implement the described functions for each specific application, but such implementation should not be considered to be beyond the scope of the present invention.

[0118] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An engine test verification system based on a virtual bench, It is characterized in that include: Control the host computer, test the host computer, ECU electronic control unit and virtual test bench; The control host computer is connected to the virtual test bench in communication. The control host computer is used to obtain control instructions, control the start of the virtual test bench, set the input quantity and initial test conditions of the virtual test bench, and receive data fed back by the virtual test bench when the virtual test bench is in operation; The test host computer is connected to the ECU electronic control unit in communication. The test host computer is used to calibrate the test parameters of the ECU electronic control unit. When executing the test, it receives, displays and saves the real-time data of the ECU electronic control unit. The ECU electronic control unit is connected to the virtual test bench in communication. The ECU electronic control unit is used to receive the control quantity of the actuator and the test parameters sensed by the sensor fed back by the virtual test bench, compare them with the target value required by the engine under the current test conditions, and control the control quantity of the virtual test bench actuator through a closed loop; The virtual test bench is used to receive the start control command, input quantity, test initial conditions and control quantity sent by the control host computer and respond, and also feed back the test data to the control host computer, and feed back the control quantity of the actuator and the test parameters sensed by the sensor to the ECU.

2. The engine test verification system based on a virtual bench according to claim 1, It is characterized in that The control host computer includes: PUMA software platform; The PUMA software platform is connected to the virtual test bench for communication. The PUMA software platform configures the engine operation information and operation time of each operating point, formulates the engine operating condition control table, issues control instructions to the engine, controls the engine operation in real time, and receives and stores the real-time operation data of the engine model.

3. The engine test verification system based on a virtual bench according to claim 1 or 2, It is characterized in that The control host computer also includes: strategy control platform; The strategy control platform is configured with multiple channels, defines the function of each channel and the execution order of multiple channels, regulates the input quantity of the virtual test bench based on multiple channels, sets the signal status of each input quantity of the virtual test bench, and switches the channels of each input signal of the virtual test bench.

4. The engine test verification system based on a virtual bench according to claim 1 or 2, It is characterized in that The test host computer includes: ETAS software platform; The ETAS software platform exchanges calibration data with the ECU electronic control unit in real time to configure the engine's performance parameters and emission characteristics; The user configures the measurement parameters of the ETAS device based on the ETAS software platform and records the output parameters and sensor signals of the ECU electronic control unit; Based on the ETAS software platform, users obtain various parameters of engine operation, compare and analyze them with the engine bench calibration values ​​to find out the differences, and adjust the different parameters within the preset limit range. At the same time, the ETAS software platform monitors and records the fault codes and error status of the ECU electronic control unit.

5. The engine test verification system based on a virtual bench according to claim 4, It is characterized in that The test host computer also includes: CAN tool software platform; The CAN tool software platform receives messages sent by the ECU electronic control unit through the J1939 protocol to determine the operating status of the engine simulated by the virtual test bench.

6. The engine test verification system based on a virtual bench according to claim 5, It is characterized in that The ECU electronic control unit communicates with the ETAS software platform through the ETAS calibration equipment, and communicates with the CAN tool software platform through the CAN bus tool; The ECU electronic control unit determines the state of the engine by reading the sensor signals and engine status quantities of the virtual test bench, and feeds back the engine status information to the test host computer; at the same time, it receives the calibration signals and control CAN messages sent by the test host computer, intervenes in the engine state simulated by the virtual test bench, and realizes closed-loop control of the measurement signal.

7. The engine test verification system based on a virtual bench according to claim 6, It is characterized in that The ECU electronic control unit controls the engine's operating state by controlling the operation of the engine's ignition coil, injector, and throttle actuator.

8. The engine test verification system based on a virtual bench according to claim 1 or 2, It is characterized in that The virtual test bench includes a real-time machine, which is equipped with an engine model and a post-processing model; The engine model and post-processing model collect bench test steady-state parameters and transient test data respectively to ensure that the simulation output parameters and bench test data are within the error range; The engine model is connected to the post-processing model in communication. The engine model sends an upstream emission data signal to the post-processing model according to the received signal. The post-processing model calculates and feeds back the downstream emission data and then sends it to the engine model.

9. The engine test verification system based on a virtual bench according to claim 1 or 2, It is characterized in that The virtual test bench is connected to the control host computer, the test host computer, and the ECU electronic control unit through the hardware communication port; The hardware communication ports include: IO interface, Ethernet interface and CAN bus interface.

10. An engine test verification method based on a virtual bench, It is characterized in that The method is used to implement the engine test verification system based on a virtual bench as described in any one of claims 1 to 9; Methods include: The control host computer obtains control instructions and controls the virtual test bench to start. The virtual test bench receives the start control instructions, input quantities, test initial conditions and control quantities sent by the ECU electronic control unit sent by the control host computer, responds, and also feeds back test data to the control host computer, and feeds back the control quantities of the actuators and the test parameters sensed by the sensors to the ECU electronic control unit; The host computer is used to test the test parameters of the ECU electronic control unit. When executing the test, the real-time data of the ECU electronic control unit is received, displayed and saved; The ECU electronic control unit receives the control quantity of the actuator fed back by the virtual test bench and the test parameters sensed by the sensor, compares them with the target value required by the engine under the current test conditions, and controls the control quantity of the virtual test bench actuator through a closed loop.

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