Controller-in-the-loop hybrid vehicle fuel consumption simulation test system

Abstract

The present invention relates to the technical field of hardware-in-the-loop testing of hybrid electric vehicles, in particular to a hybrid vehicle fuel consumption simulation test system with a controller in the loop, which includes a hardware-in-the-loop test system, a vehicle environment simulation system, a real controller, a fuel consumption test simulation system and a host computer, wherein the hardware-in-the-loop test system loaded with the vehicle environment simulation system and the fuel consumption test simulation system is connected to the real controller of the vehicle through a CAN bus and is controlled by the host computer; wherein the hardware-in-the-loop test system serves as a hardware-in-the-loop carrier, the vehicle environment simulation system simulates the vehicle operating environment by setting environmental parameters and vehicle parameters; the real controller serves as a hardware-in-the-loop control object; and the fuel consumption test simulation system simulates and completes the fuel consumption test. The test system of the present invention can simulate a hybrid vehicle to perform a WLTC fuel consumption simulation test, effectively predict and test the operating conditions and real fuel consumption of a hybrid vehicle, shorten the development cycle, and reduce development costs.

Description

Technical Field

[0001] The invention relates to the technical field of hardware-in-the-loop testing of hybrid electric vehicles, in particular to a controller-in-the-loop hybrid electric vehicle fuel consumption simulation testing system. Background Art

[0002] In order to meet national emission requirements during the development of hybrid vehicles, it is necessary to conduct power consumption (CD) and power retention (CS) tests in a third-party laboratory. The test cycle conducted by the laboratory is the WLTC (Worldwide Harmonized Light Vehicle Test Cycle). The above tests conducted in the laboratory have the problems of high testing costs, complex testing process and difficulty in adjusting the vehicle status.

[0003] The hardware-in-the-loop (HIL) test system connects to the controller and simulates the vehicle environment for simulation. It has been successfully verified that it can reduce costs and improve software development efficiency during vehicle development. At present, the fuel consumption test of hybrid vehicles, in addition to the actual fuel consumption test of the whole vehicle, is mostly calculated by software analysis. The whole vehicle test is often complicated, inefficient, and the test cost is high; the conditions for fuel consumption testing by pure software analysis are often too ideal and differ greatly from the actual situation. On this basis, by building a WLTC fuel consumption simulation test environment in the hardware-in-the-loop test system software through the host computer, the vehicle fuel consumption can be effectively estimated, and the vehicle fuel consumption control strategy development support can be provided during the controller software development stage, and the strategy can be improved and optimized in a timely manner. Summary of the invention

[0004] The technical problem to be solved by the present invention is: in order to solve the problems existing in the prior art in the above-mentioned background technology, a hybrid vehicle fuel consumption simulation test system with a controller in the loop is provided, which can effectively estimate the vehicle fuel consumption level.

[0005] The technical solution adopted by the present invention to solve the technical problem is: a controller-in-loop hybrid vehicle fuel consumption simulation test system, comprising:

[0006] Hardware-in-the-loop test system, using SCALEXIO system as real-time simulation control system,

[0007] Real controllers, including the vehicle controller and the hybrid transmission controller, participate in hardware-in-the-loop testing by running the real model software integrated into the two controllers.

[0008] The vehicle environment simulation system includes a vehicle physical model. The vehicle physical model is controlled by the hardware-in-the-loop test system to simulate the specified working conditions. The vehicle operating environment is simulated by setting environmental parameters and vehicle parameters.

[0009] A fuel consumption test simulation system, having a WLTC fuel consumption simulation model, which operates under a simulated specified operating condition and simulates a fuel consumption test through a driver speed control system;

[0010] The host computer is used to monitor and control the execution process, results and various real-time test data of the vehicle environment simulation system, real controller and WLTC fuel consumption simulation model in real time.

[0011] Furthermore, the driver speed control system includes speed feedforward regulation and speed PI regulation, and the driver speed control system controls the vehicle accelerator pedal signal and brake pedal signal through the speed feedforward regulation and PI regulation.

[0012] Furthermore, the speed feedforward regulation presets a speed feedforward time threshold, calculates the wheel-end demand torque required for the threshold time speed target according to the gearbox drag resistance, caliper resistance, road resistance, slope resistance and acceleration resistance, and calculates the brake pedal opening and accelerator pedal opening required for the threshold time speed target according to the vehicle speed-brake pedal output torque relationship and the vehicle speed-accelerator pedal output torque relationship, respectively, and passes the opening value to PI regulation.

[0013] Furthermore, the PI regulation takes the speed difference between the current vehicle speed and the target vehicle speed as a target, and quickly adjusts the speed difference to zero through a proportional-integral regulation method, and gives corresponding accelerator pedal signals and brake pedal signals.

[0014] Furthermore, the WLTC fuel consumption simulation model includes a WLTC target vehicle speed model, a driver speed control system, a fuel consumption calculation model, a brake pedal and an accelerator pedal. The fuel consumption simulation model outputs the accelerator pedal signal and the brake pedal signal to the real controller according to the driver speed control system. The vehicle controller outputs the vehicle hybrid drive mode and the actual gear position and output torque of the gearbox according to the vehicle physical model, and drives the vehicle to travel according to the target vehicle speed.

[0015] Furthermore, the driver speed control system performs a real WLTC fuel consumption test speed target following operation, the vehicle physical model responds to feedback, a fuel consumption calculation equation is constructed according to the engine universal characteristic curve, and the vehicle WLTC fuel consumption test result is simulated and calculated.

[0016] Furthermore, the SCALEXIO system includes a DS2680 I / O board and a DS2671 communication board, and the host computer is connected to the hardware-in-the-loop test system via the DS2671 communication board.

[0017] Furthermore, the real controller is connected to the hardware-in-the-loop test system via a CAN bus communication.

[0018] Furthermore, the vehicle physical model includes an engine power model, a chassis transmission model, a power battery model, a power motor model, an accessory system model and a low-voltage system model, and all of the above models are Simulink models.

[0019] Further, the environmental parameters include environmental temperature parameters and road resistance parameters, and the vehicle parameters include vehicle tire parameters and vehicle weight parameters.

[0020] The beneficial effects of the present invention are as follows: the test system can be used to predict and simulate the operating conditions and actual fuel consumption of the WLTC fuel consumption test when the vehicle is under control strategy development, shorten the hybrid vehicle development cycle, and reduce the hybrid vehicle development cost;

[0021] In the present invention, the vehicle environment simulation system and the fuel consumption test simulation system can be calibrated in real time by the host computer, so that the vehicle environment simulation system can be operated according to the vehicle fuel consumption test conditions, and the WLTC fuel consumption simulation test results can be made consistent with the actual test results of the WLTC laboratory, thereby improving the control ability of the fuel consumption control strategy of the real controller, and providing an accurate optimization direction for subsequent fuel consumption optimization;

[0022] The driver speed control system of the present invention controls the brake pedal and the accelerator pedal through feedforward regulation and PI regulation. The system has high control accuracy and fast responsiveness, can effectively meet the driver's task of simulating following the target speed curve, and accurately simulates the speed control of the whole vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0024] Figure 1 This is a structural block diagram of the controller-in-loop hybrid vehicle fuel consumption simulation test system of the present invention.

[0025] Figure 2 It is a structural block diagram of the fuel consumption test simulation system in the present invention.

[0026] Figure 3 It is a structural block diagram of the driver speed control system in the present invention.

[0027] Figure 4 It is a line graph of the relationship between vehicle speed and brake pedal output torque in the present invention.

[0028] Figure 5 It is a line graph of the relationship between vehicle speed and accelerator pedal output torque in the present invention. DETAILED DESCRIPTION

[0029] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, which only illustrate the basic structure of the present invention in a schematic manner, and therefore only show the components related to the present invention.

[0030] like Figure 1 As shown, a controller-in-loop hybrid vehicle fuel consumption simulation test system includes a hardware-in-loop test system, a real controller, a vehicle environment simulation system, a fuel consumption test simulation system and a host computer. The vehicle environment simulation system and the fuel consumption test simulation system are loaded into the hardware-in-loop test system through Simulink (a graphical programming environment developed by MathWorks for simulating, analyzing and designing dynamic systems), the real controller is connected to the hardware-in-loop test system through CAN bus communication, and the host computer is connected to the hardware-in-loop test system through a communication board.

[0031] This embodiment uses the SCALEXIO real-time simulation control system of the dSPACE system as the carrier of the hardware-in-the-loop test system, including the DS2680 I / O board and the DS2671 communication board. The vehicle environment simulation system includes a physical model of the vehicle, environmental parameters and vehicle parameters, and simulates the actual operating conditions of the vehicle by setting environmental parameters and vehicle parameters. Environmental parameters include ambient temperature parameters and road resistance parameters, and vehicle parameters include vehicle tire parameters and vehicle weight parameters. The real controller, namely the vehicle controller (HCU) and the hybrid transmission controller (TCU), participates in the simulation test by running the built-in integrated control strategy. The fuel consumption test simulation system includes a WLTC fuel consumption simulation model, which simulates the fuel consumption test through a driver speed control system. The host computer is used to monitor and control the execution process, results and various real-time test data of the vehicle environment simulation system, the real controller and the WLTC fuel consumption simulation model in real time.

[0032] The vehicle physical model includes the engine power model, chassis transmission model, power battery model, power motor model, accessory system model, and low-voltage system model. Figure 2 As shown, the WLTC fuel consumption simulation model includes a WLTC target vehicle speed model, a driver speed control system, a fuel consumption calculation model, a brake pedal and an accelerator pedal.

[0033] like Figure 3 As shown, the driver speed control system includes speed feedforward regulation and speed PI regulation. The speed feedforward regulation includes feedforward time threshold, wheel end demand torque, vehicle speed-brake pedal output torque relationship, vehicle speed-accelerator pedal output torque relationship, brake pedal opening and accelerator pedal opening.

[0034] The host computer includes the control software ControlDesk of the hardware-in-the-loop test system (experiment debugging software developed by dSPACE with calibration and diagnosis functions). ControlDesk can perform real-time observation, calibration and analysis of variables, so that the host computer can monitor the simulation execution results of the vehicle environment simulation system model by controlling the hardware-in-the-loop test system variables loaded into the vehicle environment simulation system model and the fuel consumption test simulation system, and controlling the vehicle's real controller (HCU and TCU) through the XCP protocol (a communication protocol for calibration and measurement of automotive electronic control units (ECUs)) and the CAN bus. It can also monitor and analyze various real-time data fed back by the hardware-in-the-loop, thereby monitoring the results of the WLTC fuel consumption simulation analysis.

[0035] The hardware-in-the-loop test system that has been loaded with the vehicle environment simulation system model and the fuel consumption test simulation system can respond to the control instructions of the host computer, and can control the vehicle physical model in the vehicle environment simulation system model to operate according to the specified working conditions, and can also control the driver longitudinal speed system in the fuel consumption test simulation system to operate according to the specified working conditions. The host computer variable control can display and calibrate the vehicle physical model operating parameters and vehicle environmental parameters in real time, and control the adjustment of the control strategy variables of the real controller of the vehicle. Through the host computer simulation of the WLTC fuel consumption test process, the variables controlled by the host computer and the real-time simulation data results can be realized in the host computer by means of visualization through buttons to realize variable control and through pointers to realize parameter simulation, including key control, gear control, driving mode selection and other simulated cab operation simulation, to realize the display of vehicle tachometer, speedometer, SOC display, 100km fuel consumption and other parameters.

[0036] In this embodiment, the settings of the ambient temperature and road resistance parameters in the vehicle environment simulation system, the vehicle tire radius parameters, and the vehicle weight parameters will serve as important influencing factors of the external environment of the WLTC fuel consumption simulation test. The adjustment of the ambient temperature can simulate the battery charging and discharging internal resistance at different temperatures, and the battery 1 / 30 / 60s charging and discharging peak power; the setting of the road resistance parameters can simulate the WLTC laboratory hub resistance. Select the real parameters to participate in the fuel consumption simulation test. By comparing with the real fuel consumption values ​​in the laboratory, the parameters of the vehicle environment simulation system can be adjusted in reverse to estimate the vehicle fuel consumption, providing a basis for the direction of controller strategy development.

[0037] In this embodiment, the WLTC laboratory hub resistance is simulated by setting the road resistance parameters in the vehicle environment simulation system. The adjustment of the road resistance parameters will affect the output of the vehicle wheel end required torque. According to the control strategy of the real controller HCU, it will affect the running time of the WLTC cycle low-speed EV mode (pure electric mode). To ensure the power balance (SOC), it will affect the engine start time point, thereby affecting the fuel consumption value. For every 10N decrease in road resistance, the WLTC fuel consumption cycle will decrease by 0.1L / 100km.

[0038] In this embodiment, the WLTC vehicle speed cycle curve is set as the vehicle operation target model in the WLTC fuel consumption simulation model, and the hardware-in-the-loop test system and the real controller run the vehicle control strategy. The fuel consumption simulation model outputs the accelerator pedal signal and the brake pedal signal to the hard-line accelerator and brake signal interface of the real controller HCU according to the driver's speed control system. The HCU outputs the vehicle hybrid drive mode and the actual gear position of the gearbox according to the engine, battery, motor and chassis transmission model, outputs torque, and drives the vehicle to travel according to the target speed.

[0039] In this embodiment, the driver speed control system controls the vehicle accelerator pedal signal and brake pedal signal through speed feedforward regulation and PI regulation. Speed ​​feedforward regulation requires setting a speed feedforward time threshold. In this embodiment, the time threshold is set to 0.6s, that is, the vehicle speed value 0.6s before the WLTC cycle target speed curve is used as the feedforward speed target value. At the first 0.6s speed target, the wheel end required torque required for the first 0.6s speed target is calculated based on the gearbox drag resistance, caliper resistance, road resistance, ramp resistance and acceleration resistance, and the wheel end required torque is calculated based on the vehicle speed-brake pedal output torque relationship (such as Figure 4 As shown in the figure, the horizontal axis is the vehicle speed, the vertical axis is the brake pedal travel, and the corresponding data is the torque value; different calibration parameters will result in different torque values, so the relationship diagram can be formed based on the actual vehicle data, and then the corresponding torque value can be found based on the relationship diagram) and the vehicle speed-accelerator pedal output torque relationship (such as Figure 5As shown in the figure, the horizontal axis is the vehicle speed, the vertical axis is the accelerator pedal opening, and the corresponding data is the torque value; different calibration parameters will obtain different torque values, so the relationship diagram can be formed according to the actual vehicle data first, and then the corresponding torque value can be found according to the relationship diagram) to calculate the brake pedal opening and accelerator pedal opening required for the vehicle speed target in the first 0.6s, and pass the opening value to PI regulation. The PI regulation method takes the speed difference between the current vehicle speed and the target vehicle speed as the target. Through the proportional-integral regulation method, the speed difference is adjusted to zero with extremely high precision and stability in a very short time, and the corresponding accelerator pedal signal and brake pedal signal are given. On the basis of the accelerator pedal signal and brake pedal signal transmitted by the speed feedforward regulation, the accelerator opening and brake opening required for the PI difference regulation are added to form the accelerator pedal signal and brake pedal signal of the driver speed control system. On this basis, the abnormal accelerator pedal signal and brake pedal signal with ultra-high frequency changes are filtered out by setting a low-pass filter, and finally transmitted to the real controller HCU as a relatively stable signal. The driver speed control system can accurately and effectively simulate the actual driver's driving situation through the combined control of speed feedforward regulation and PI regulation, ensuring that the vehicle operates in accordance with the requirements of the WLTC cycle.

[0040] In this embodiment, the real controllers HCU and TCU calculate the required driving power of the vehicle according to the physical model of the vehicle, select the required engine working mode and the actual gear position of the transmission based on the hybrid vehicle power drive mode, and finally output the engine control signal and the dual-motor control signal, which are sent to the hardware-in-the-loop test system.

[0041] In this embodiment, the real controller HCU reads the power battery SOC through the hardware-in-the-loop test system, and controls the engine starting point and the hybrid vehicle power driving mode in the WLTC cycle according to the energy consumption of the power motor and the kinetic energy braking recovery, realizes the switching between EV and HEV modes (hybrid mode), and realizes the parallel and series selection of the hybrid system to meet the power balance requirements of the WLTC fuel consumption test.

[0042] In this embodiment, the WLTC simulated fuel consumption value retrieves the engine universal characteristic curve through the engine speed value and the torque value, multiplies the engine fuel consumption efficiency value corresponding to the curve by the engine speed value, and integrates to calculate the fuel consumption; and calculates the vehicle mileage under the WLTC cycle according to the vehicle speed integral; divides the calculated fuel consumption by the vehicle mileage to obtain the fuel consumption value per 100 kilometers, in units of L / 100Km.

[0043] Based on the above ideal embodiments of the present invention, the relevant staff can make various changes and modifications without departing from the technical concept of the present invention through the above description. The technical scope of the present invention is not limited to the contents of the specification, and its technical scope must be determined according to the scope of the claims.

Claims

1. A controller-in-loop hybrid vehicle fuel consumption simulation test system, characterized in that: include: Hardware-in-the-loop test system, using SCALEXIO system as real-time simulation control system, Real controllers, including the vehicle controller and the hybrid transmission controller, participate in hardware-in-the-loop testing by running the real model software integrated into the two controllers. The vehicle environment simulation system includes a vehicle physical model. The vehicle physical model is controlled by the hardware-in-the-loop test system to simulate the specified working conditions. The vehicle operating environment is simulated by setting environmental parameters and vehicle parameters. A fuel consumption test simulation system, having a WLTC fuel consumption simulation model, which operates under a simulated specified operating condition and simulates a fuel consumption test through a driver speed control system; The host computer is used to monitor and control the execution process, results and various real-time test data of the vehicle environment simulation system, real controller and WLTC fuel consumption simulation model in real time; The driver speed control system includes speed feedforward regulation and speed PI regulation, and the driver speed control system controls the vehicle accelerator pedal signal and brake pedal signal through speed feedforward regulation and PI regulation; The speed feedforward regulation pre-sets a speed feedforward time threshold, calculates the wheel end required torque required for the threshold time vehicle speed target according to the gearbox drag resistance, caliper resistance, road resistance, slope resistance and acceleration resistance, calculates the brake pedal opening and accelerator pedal opening required for the threshold time vehicle speed target according to the vehicle speed-brake pedal output torque relationship and the vehicle speed-accelerator pedal output torque relationship, and transmits the opening to the PI regulation; The PI regulation takes the speed difference between the current vehicle speed and the target vehicle speed as the target, and quickly adjusts the speed difference to zero through the proportional-integral regulation method, and gives the corresponding accelerator pedal signal and brake pedal signal; On the basis of the accelerator pedal signal and brake pedal signal transmitted by the speed feedforward regulation, the accelerator opening and brake opening required by the PI regulation are added to form the accelerator pedal signal and brake pedal signal of the driver speed control system. On this basis, a low-pass filter is set to filter out abnormal accelerator pedal signals and brake pedal signals with ultra-high frequency changes, and finally transmit them to the real controller in the form of stable signals.

2. The controller-in-the-loop hybrid vehicle fuel consumption simulation test system according to claim 1 is characterized in that: The WLTC fuel consumption simulation model includes a WLTC target vehicle speed model, a driver speed control system, a fuel consumption calculation model, a brake pedal and an accelerator pedal. The fuel consumption simulation model outputs the accelerator pedal signal and the brake pedal signal to the real controller according to the driver speed control system. The vehicle controller outputs the vehicle hybrid drive mode and the actual gear position and output torque of the gearbox according to the vehicle physical model, and drives the vehicle to travel according to the target vehicle speed.

3. The controller-in-the-loop hybrid vehicle fuel consumption simulation test system according to claim 1 is characterized in that: The driver speed control system performs a real WLTC fuel consumption test speed target following operation, the vehicle physical model responds to feedback, a fuel consumption calculation equation is constructed according to the engine universal characteristic curve, and the vehicle WLTC fuel consumption test result is simulated and calculated.

4. The controller-in-the-loop hybrid vehicle fuel consumption simulation test system according to claim 1 is characterized in that: The SCALEXIO system includes a DS2680 I / O board and a DS2671 communication board, and the host computer is connected to the hardware-in-the-loop test system via the DS2671 communication board.

5. The controller-in-the-loop hybrid vehicle fuel consumption simulation test system according to claim 1 is characterized in that: The real controller is connected to the hardware-in-the-loop test system via a CAN bus communication.

6. The controller-in-the-loop hybrid vehicle fuel consumption simulation test system according to claim 1 is characterized in that: The vehicle physical model includes an engine power model, a chassis transmission model, a power battery model, a power motor model, an accessory system model and a low-voltage system model, and all of the above models are Simulink models.

7. The controller-in-the-loop hybrid vehicle fuel consumption simulation test system according to claim 1 is characterized in that: The environmental parameters include environmental temperature parameters and road resistance parameters, and the vehicle parameters include vehicle tire parameters and vehicle weight parameters.

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