Hardware-in-the-loop system and method for testing thereof

Abstract

The application relates to a hardware-in-the-loop system and a testing method thereof. The hardware-in-the-loop system is suitable for an aero-engine controller and mainly comprises an upper computer interaction system, a real-time simulation system, an interface matching system and a signal conditioning system. The upper computer interaction system is used for establishing test cases and configuration information of the hardware-in-the-loop system; the real-time simulation system receives the test cases and the configuration information sent by the upper computer interaction system, and the real-time simulation system tests the test cases; the interface matching system is coupled to the upper computer interaction system, the interface matching system comprises a matrix relay switch and a connector connected with the matrix relay switch, and the connector of the interface matching system is matched and connected with a connector of the aero-engine controller through a special test cable. Through the scheme provided by the application, the working efficiency of testing can be improved, and the research and development cost is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of aero-engine testing, in particular to a hardware-in-the-loop system and a testing method thereof. BACKGROUND

[0002] The hardware-in-the-loop system simulates the running state of a controlled object by running a simulation model on a real-time processor, connects with a measured controller through an I / O interface, and tests the measured device in all aspects and systematically.

[0003] For an aero-engine controller, the existing hardware-in-the-loop system is usually customized and developed according to the electrical signal characteristics, quantity and connector type of the controller. When the engine controller is replaced or the I / O signal collection of the hardware-in-the-loop system is abnormal, the hardware-in-the-loop system cannot be used. At the same time, when performing the hardware-in-the-loop test, only after executing a test case, manually switching the test case, and then executing the next test case, can the next test case be executed. In the test process, if the operator does not find abnormal test data, problem troubleshooting can only be performed in the data analysis stage. Therefore, the existing hardware-in-the-loop system has many inconveniences such as high use cost, much repeated work, low work efficiency, poor reliability, etc. SUMMARY

[0004] The technical problem to be solved by the present application is to provide a hardware-in-the-loop system and a testing method thereof, which can improve the work efficiency of testing and reduce the research and development cost.

[0005] To solve the above technical problems, the present application provides a hardware-in-the-loop system suitable for an aero-engine controller, comprising:

[0006] An upper computer interaction system for establishing a test case and configuration information of the hardware-in-the-loop system;

[0007] A real-time simulation system for receiving the test case and configuration information sent by the upper computer interaction system, and testing the test case;

[0008] An interface matching system coupled to the upper computer interaction system, the interface matching system comprising a matrix relay switch and a connector connected to the matrix relay switch, and the connector of the interface matching system being matched and connected to the connector of the aero-engine controller through a special test cable;

[0009] A signal conditioning system coupled to the real-time simulation system, the signal conditioning system being capable of adjusting the state of the matrix relay switch to match and connect the connector of the interface matching system to the connector of the aero-engine controller.

[0010] According to an embodiment of the present application, the host computer interaction system and the real-time simulation system communicate via Ethernet.

[0011] According to an embodiment of the present application, the host computer interaction system and the interface matching system communicate via Ethernet.

[0012] The present application also provides an automatic test method applied to the aforementioned hardware-in-the-loop system, which comprises:

[0013] Step S1, selecting the aero-engine controller and a special test cable;

[0014] Step S2, the connector of the interface matching system is matched and connected with the connector of the aero-engine controller via the special test cable;

[0015] Step S3, powering on the hardware-in-the-loop system;

[0016] Step S4, entering the host computer interaction system, establishing a test project, and managing the test configuration under the directory of the test project;

[0017] Step S5, completing the test case set editing;

[0018] Step S6, executing the test on the test case;

[0019] Step S7, saving the test data.

[0020] According to an embodiment of the present application, the automatic test method further comprises:

[0021] Step S8, selecting the test data;

[0022] Step S9, generating a test report;

[0023] Step S10, judging whether the test meets the requirements, if not, returning to step S4;

[0024] Step S11, completing the test.

[0025] According to an embodiment of the present application, step S4 comprises:

[0026] Step S41, performing hardware resource management configuration;

[0027] Step S42, matching the logic quantity relationship in the simulation model of the real-time simulation system with the connector connection relationship of the interface matching system via interface control file management;

[0028] Step S43, selection and configuration of the simulation model;

[0029] Step S44, a test case set is established, and the test case set comprises a plurality of independent test cases;

[0030] According to an embodiment of the present application, step S41 further comprises:

[0031] Step S411, a mapping connection relationship of matching the connector of the interface matching system with the connector of the aero-engine controller is established;

[0032] Step S412, the state of the matrix relay switch is adjusted to change the mapping connection relationship and realize channel switching;

[0033] Step S413, a feedback of whether the setting of the matrix relay switch is successful or not is sent.

[0034] According to an embodiment of the present application, in step S43, a running simulation model and a platform for compiling the simulation model, interface information of input and output of the simulation model, simulation model solving time, simulation model scheduling time sequence and simulation model input and output and other simulation model and data stream information of data acquisition are selected.

[0035] According to an embodiment of the present application, step S44 comprises:

[0036] Step S441, a test outline document is imported to form a test requirement;

[0037] Step S442, the test case is edited;

[0038] Step S443, test criteria are edited;

[0039] Step S444, the test case set editing is completed.

[0040] According to an embodiment of the present application, in step S441, the test case is set with communication time, variable name, condition judgment and compiling language selection mode.

[0041] The hardware-in-the-loop system and the test method provided by the present application can complete comprehensive and automatic test of the test case of the aero-engine control software, improve test efficiency and effectively reduce cost.

[0042] It should be understood that the above general description and the following detailed description of the present application are exemplary and illustrative, and are intended to provide further explanation of the present application as claimed. BRIEF DESCRIPTION OF DRAWINGS

[0043] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the specific embodiments of the present application are described in detail below with reference to the accompanying drawings, in which:

[0044] Figure 1A schematic diagram of the hardware-in-the-loop system according to an embodiment of the present invention is shown;

[0045] Figure 2 A schematic diagram showing the connection between the interface matching system and the engine controller in one embodiment of the present invention is shown;

[0046] Figure 3 A logic diagram of a matrix relay switch according to an embodiment of the present invention is shown;

[0047] Figure 4 A flowchart of an automatic testing method according to an embodiment of the present invention is shown.

[0048] The above figures include the following reference numerals:

[0049] Hardware-in-the-loop system 100; Host computer interaction system 101

[0050] Real-time simulation system 102 Interface matching system 103

[0051] Signal conditioning system 104 Engine controller 105

[0052] Matrix relay switch 106, dedicated test cable 107 Detailed Implementation

[0053] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0054] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and therefore the invention is not limited to the specific embodiments disclosed below.

[0055] As indicated in this application and claims, unless the context clearly indicates otherwise, the words "a," "an," "an," and / or "the" are not specifically singular and may include plural forms. Generally speaking, the terms "comprising" and "including" only indicate the inclusion of explicitly identified steps and elements, which do not constitute an exclusive list, and the method or apparatus may also include other steps or elements.

[0056] In detailing the embodiments of this application, for ease of explanation, the cross-sectional views illustrating the device structure will be partially enlarged and not to scale. Furthermore, the schematic diagrams are merely examples and should not limit the scope of protection of this application. In actual fabrication, the three-dimensional spatial dimensions of length, width, and depth should be included.

[0057] For the sake of convenience, the phrases "on", "above", "lower", "below", "upper", "top", and the like in the description can be used to describe one element or feature's relationship to another element or feature within the drawing. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientations depicted in the drawings. For example, if a device is inverted or rotated 90 degrees, then an element described as "below" or "beneath" another element or feature would now be oriented "above" or "over" the other element or feature. Thus, the example terms "below" and "under" can encompass both an orientation of above and below. The device can be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Well, it will be further understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientations depicted in the drawings. For example, if a layer is referred to as being "between" two layers, it can be the only layer between the two layers, or one or more intervening layers can also be present.

[0058] In the context of the present application, a structure described as having a first feature "on" a second feature can include embodiments in which the first and second features are formed in direct contact, as well as embodiments in which additional features are formed between the first and second features, such that the first and second features can not be in direct contact.

[0059] Figure 1 A structural schematic diagram of a hardware-in-the-loop system of an embodiment of the present application is shown. Figure 2 A connection schematic diagram of an interface matching system and an engine controller in an embodiment of the present application is shown. Figure 3 A logic diagram of a matrix relay switch of an embodiment of the present application is shown. Figure 1 As shown, the present application provides a hardware-in-the-loop system 100 suitable for an aero-engine controller 105, mainly including a host computer interaction system 101, a real-time simulation system 102, an interface matching system 103, and a signal conditioning system 104.

[0060] The host computer interaction system 101 is configured to establish test cases and configuration information of the hardware-in-the-loop system 100.

[0061] The real-time simulation system 102 receives the test cases and the configuration information sent by the host computer interaction system 101, and the real-time simulation system 102 tests the test cases.

[0062] The interface matching system 103 is coupled to the host computer interaction system 101. The interface matching system 103 includes a matrix relay switch 106 and a connector connected to the matrix relay switch 106. The connector of the interface matching system 103 is matched and connected to the connector of the aero-engine controller 105 through a special test cable 107.

[0063] The signal conditioning system 104 is coupled to the real-time simulation system 102. The signal conditioning system 104 can adjust the state of the matrix relay switch 106 to match the connector of the interface matching system 103 with the connector of the aero-engine controller 105.

[0064] The present invention provides a hardware-in-the-loop system 100 that, when replacing the engine controller 105 or when some I / O signals are abnormal, adjusts the state of the matrix relay switch 106 to match the connector of the interface matching system 103 with the connector of the aircraft engine controller 105, thereby improving testing efficiency.

[0065] like Figure 2 As shown, the connectors of the interface matching system 103 are connected to the connectors of the aircraft engine controller 105 via a dedicated test cable 107. The connection sequence of the connectors is as follows: all connectors on the engine controller 105 are grouped together and connected to connector X1 in the interface matching system 103 via a dedicated test cable 107, with each signal line using a shielded design. The signal conditioning system 104 is connected to the interface matching system 103. Terminal 1 of connector J1 of the engine controller 105 is connected to terminal 1 of connector X1 of the interface matching system 103, terminal 2 of connector J1 is connected to terminal 2 of connector X1, and so on. After terminal 10 of connector J1 is connected, at least 5 gaps are reserved for connector X1. Terminal 1 of connector J2 is connected to terminal 16 of connector X1, and terminal 2 of connector J2 is connected to terminal 17 of connector X1. Taking the relationship between engine controller 105 connector J1 and dedicated test cable 107 as an example, the mapping connection from connector J1 to connector X1 of interface matching system 103 is described. In one embodiment, terminals 1 and 2 of engine controller 105 connector J1 are the "+" and "-" terminals of the RTD signal, connected to terminals 1 and 2 of connector X1 of interface matching system 103. Combined with... Figure 3 As shown, in the initial state, the matrix relay switch 106 is fully open. Based on the known terminal information of connector X1, the signal conditioning system 104 adjusts the state of the matrix relay switch 106, mapping the terminal information of connector X1 to the signal conditioning terminal information. Specifically, terminals 1 and 2 of connector J1 are connected to a set of good RTD signals output by the signal conditioning system 104. Similarly, terminals 3 and 4 of connector J1 are connected to a set of thermocouple signals output by the signal conditioning system 104. When the engine controller 105 is replaced or a channel is damaged, only the matrix relay switch 106 in the interface matching system 103 needs to be modified to change the mapping relationship, thus completing the switching between channels.

[0066] Preferably, the host computer interaction system 101 and the real-time simulation system 102 communicate via Ethernet.

[0067] Preferably, the host computer interaction system 101 and the interface matching system 103 communicate via Ethernet.

[0068] The present application also provides an automatic testing method applied to the aforementioned hardware-in-the-loop system 100, which comprises the following steps:

[0069] Step S1, selecting the aero-engine controller 105 and the special test cable 107. When the hardware-in-the-loop system 100 is tested, the aero-engine controller 105 to be tested is first selected, and the special test cable 107 and the connector information of the aero-engine controller 105 to be used for testing are determined according to the technical state of the aero-engine controller 105. In fact, the state of the aero-engine controller 105 is changed only by changing the connector information of the port of the aero-engine controller 105, while the connector information of the interface matching system 103 is not changed.

[0070] According to the principle of the aero-engine controller 105, the signals commonly used by the aero-engine controller 105 include thermocouple signals, thermal resistance signals, resolver signals, LVDT signals, etc. The difference between the aero-engine controllers 105 lies in the signal accuracy and the number of signals, so in this embodiment, a redundant design is adopted to reserve a connector gap to prevent the hardware-in-the-loop system 100 from being unable to be used due to insufficient number of signals or channel damage.

[0071] Step S2, the connectors of the interface matching system 103 are matched and connected with the connectors of the aero-engine controller 105 through the special test cable 107. As described above, referring to Figure 2 , the connection sequence of the connectors is to collect all the connectors at the aero-engine controller 105 end together, and then connect them to the connector X1 in the interface matching system 103 by using a special test cable 107, wherein a shielded wire design is used between each signal line. The signal conditioning system 104 is connected with the interface matching system 103. The No. 1 terminal of the connector J1 of the aero-engine controller 105 is connected with the No. 1 terminal of the connector X1 of the interface matching system 103, the No. 2 terminal of the connector J1 is connected with the No. 2 terminal of the connector X1, and so on. When the No. 10 terminal of the connector J1 is connected, at least 5 connector gaps are reserved for the connector X1. The No. 1 terminal of the connector J2 is connected with the No. 16 terminal of the connector X1, the No. 2 terminal of the connector J2 is connected with the No. 17 terminal of the connector X1, and a connector gap is reserved. In this way, the matching connection of all the connectors is completed.

[0072] Step S3, the hardware-in-the-loop system 100 is powered on. The hardware-in-the-loop system 100 completes the communication of the host computer interaction system 101, the device self-checking (including the engine controller 105, the real-time simulation system 102) according to the initialization configuration, etc. This process follows the current mainstream conventional operation mode.

[0073] Step S4, the host computer interaction system 101 is entered, the test project is established, and the test configuration is managed under the directory of the test project.

[0074] Step S5, the test case set editing is completed.

[0075] Step S6, the test case is executed. The test case set is executed, and the test case execution situation can be viewed in the graphic monitoring interface or the test case debugging interface. The host computer interaction system 101 uniformly transmits the set test case and the configuration information to the real-time simulation system 102, and the system automatically tests according to the setting under the test case set. After one test case is executed, the host computer interaction system pops up the test pass and test data interface. If the test meets the test criterion and there is no human intervention, the interface is closed according to the system setting interface display time, the next test case is executed, if the test does not meet the test criterion or the human intervention, the system terminates the execution of the next test case, and the automatic test is ended.

[0076] Step S7, the test data is saved. After the test case set is executed, the system automatically saves all the test data in the test process, and matches the data with the test case. The test data in the test process can be viewed in the historical data. The test data is saved in the form of XML, and the display is the test data parsed after the interface control (ICD) file and the interface matching.

[0077] Preferably, the automatic test method further comprises:

[0078] Step S8, the test data is selected. Since all the test data in the test process is recorded, the storage capacity is large. In this step, the data selection is performed, and the user can selectively view.

[0079] Step S9, the test report is generated. After the test data to be analyzed is selected, the tester needs to edit the test report template. In the report template, the tester can customize the graphic drawing in the test running process, can modify the test pass index, can add the test variables to be observed, etc. Clicking the test report generation, the test data, the expected data based on the test criterion, the test pass based on the modification, the test accuracy, and the test whole process running curve drawn according to the tester selection are displayed in the report.

[0080] Step S10, judging whether the test meets the requirements, if not, returning to step S4.

[0081] Step S11, completing the test.

[0082] Preferably, step S4 comprises:

[0083] Step S41, performing hardware resource management configuration. Establishing mapping between logical channels and physical channels defined in the "hardware resource" and modifying.

[0084] Step S42, matching logical quantity relationship in the simulation model of the real-time simulation system 102 with the connector connection relationship of the interface matching system 103 through interface control file management. Taking the 1st terminal and the 2nd terminal of the engine connector J1 in the interface matching system 103 as an example, if the group of thermocouple signals represent the high-pressure compressor outlet total temperature signal, the interface position of the high-pressure compressor outlet total temperature in the simulation model needs to be mapped with the position set in the interface matching system 103. Figure 2

[0085] Step S43, selection and configuration of the simulation model.

[0086] Step S44, establishing a test case set, which contains multiple independent test cases.

[0087] Preferably, step S41 further comprises:

[0088] Step S411, establishing mapping connection relationship between the connector of the interface matching system 103 and the connector of the aero-engine controller 105. Specifically, taking the relationship between the engine controller 105 connector J1 and the special test cable 107 as an example to establish mapping connection between the 1st terminal and the 2nd terminal of the connector J1 and the 1st terminal and the 2nd terminal of the interface matching system 103 connector X1. In an embodiment, the 1st terminal and the 2nd terminal of the engine controller 105 connector J1 are "+" and "-" terminals of the thermistor signal, and the 1st terminal and the 2nd terminal of the interface matching system 103 connector X1 are connected.

[0089] Step S412, adjusting the state of the matrix relay switch 106 to change the mapping connection relationship and realize channel switching. In combination with Figure 2 and Figure 3 ​As shown, in the initial state, the matrix relay switch 106 is in the all-off state, and according to the acquired connector X1 terminal information, the signal conditioning system 104 adjusts the state of the matrix relay switch 106 to map the connector X1 terminal information to the signal conditioning terminal information, that is, to connect the No. 1 and No. 2 terminals of the connector J1 to a set of good thermistor signals output by the signal conditioning system 104. Similarly, the No. 3 and No. 4 terminals of the connector J1 are connected to a set of thermocouple signals output by the signal conditioning system 104. When the engine controller 105 is replaced or the channel is damaged, it is only necessary to modify the matrix relay switch 106 in the interface matching system 103 to change the mapping relationship, so as to complete the switching between channels.

[0090] Step S413: Send a feedback on whether the setting of the matrix relay switch 106 is successful or not.

[0091] Preferably, in step S43, the running simulation model and the platform for compiling the simulation model, the interface information for configuring the input and output of the simulation model, the simulation model solving time, the simulation model scheduling time sequence, and the simulation model input and output and other simulation model and data acquisition data stream information are selected. When configuring this information, the configuration information can be loaded by exporting to Excel and editing in Excel, and then importing the Excel file, or by configuring through a man-machine interaction interface.

[0092] Preferably, step S44 includes:

[0093] Step S441: Import the test outline document to form the test requirements. The test preview can be generated according to the imported Word document, and the tester can confirm whether all test requirements are included according to the test preview. If all test items are included, click to confirm, and if test items are missing, the tester can manually generate test requirements according to the Word document.

[0094] Step S442: Edit the test case. According to the generated test task list, the same or similar test cases are searched from the public library of test cases, and if they exist, they are added, and if there are no same test cases, the tester edits them.

[0095] Step S443, test criterion editing. According to the test task list, the same or similar test criterion is searched from the public library, if there is, it is added, if there is no same test criterion, the tester edits. In the test criterion editing, the tester can define the test boundary, set the variable expected value, specify whether the expected value is continuous judgment or terminal value judgment, and can set the mathematical formula of the expected value continuous judgment compliance, such as linear first function, triangular function, square wave function, etc. The tester needs to match the test case with the test criterion, if there is no match, the automatic execution of the test case cannot be executed but the test report can still be generated; one test case can match multiple test criteria at the same time.

[0096] Step S444, the test case set editing is completed, that is, the test is associated with the test outline, test case, test criterion, and the related test case set editing work is completed.

[0097] Preferably, in step S441, the test case is set with communication time, variable name, condition judgment, and compilation language selection mode. At the same time, the form of importing the XML file is supported to be automatically converted into the test case recognized by the system through the script. The tester can match the test item with the test case, which is convenient for calculating the test coverage rate when executing the test case set and editing the test case. After all the test cases are edited according to the test task list, all the test cases are added to the test case set.

[0098] The hardware-in-the-loop system and the test method thereof provided by the application have the following beneficial effects:

[0099] (1) The use efficiency of the hardware-in-the-loop system is improved, and the use cost of research and development is reduced;

[0100] (2) The dependence on the tester in the test process is reduced;

[0101] (3) The work efficiency of the test is improved.

[0102] Although the application has been described with reference to the current specific embodiments, those skilled in the art should recognize that the above embodiments are only used to illustrate the application, and various equivalent changes or replacements can be made without departing from the spirit of the application, therefore, the changes and modifications of the above embodiments within the scope of the spirit of the application will fall within the scope of the claims of the application.

Claims

1. A hardware-in-the-loop system suitable for an aero-engine controller, comprising: a host computer interaction system for establishing test cases and configuration information of the hardware-in-the-loop system; a real-time simulation system receiving the test cases and the configuration information sent by the host computer interaction system, the real-time simulation system testing the test cases; an interface matching system coupled to the host computer interaction system, the interface matching system comprising a matrix relay switch and a connector connected to the matrix relay switch, the connector of the interface matching system being matched and connected to the connector of the aero-engine controller through a special test cable; a signal conditioning system coupled to the real-time simulation system, the signal conditioning system being capable of adjusting the state of the matrix relay switch to match and connect the connector of the interface matching system to the connector of the aero-engine controller.

2. The hardware-in-the-loop system of claim 1, wherein, The host computer interaction system and the real-time simulation system communicate in an Ethernet mode.

3. The hardware-in-the-loop system of claim 1, wherein, The host computer interaction system and the interface matching system communicate in an Ethernet mode.

4. An automatic testing method applied to the hardware-in-the-loop system of any one of claims 1 to 3, the automatic testing method comprising: Step S1, selecting the aero-engine controller and the special test cable; Step S2, the connector of the interface matching system being matched and connected to the connector of the aero-engine controller through the special test cable; Step S3, powering on the hardware-in-the-loop system; Step S4, entering the host computer interaction system, establishing a test project, and managing test configurations under the directory of the test project; Step S5, completing test case set editing; Step S6, testing the test cases; Step S7, saving test data.

5. The automatic testing method of claim 4, wherein, Further comprising: Step S8, selecting the test data; Step S9, generating a test report; Step S10, judging whether the test meets the requirements, if not, returning to Step S4; Step S11, completing the test.

6. The automatic testing method of claim 4, wherein, Step S4 comprises: Step S41, performing hardware resource management configuration; Step S42, matching the logical quantity relationship in the simulation model of the real-time simulation system with the connector connection relationship of the interface matching system through interface control file management; Step S43, selecting and configuring the simulation model; Step S44, establishing a test case set, the test case set comprising a plurality of independent test cases.

7. The automatic testing method of claim 6, wherein, Step S41 further comprises: Step S411, establishing a mapping connection relationship of the connector of the interface matching system matched with the connector of the aero-engine controller; Step S412, adjusting the state of the matrix relay switch to change the mapping connection relationship to realize channel switching; Step S413, sending a feedback of whether the matrix relay switch setting is successful.

8. The automatic testing method of claim 6, wherein, In Step S43, a running simulation model and a platform for compiling the simulation model, interface information of input and output of the simulation model, simulation model solving time, simulation model scheduling time sequence, and data stream information of simulation model input and output and other simulation models and data acquisition are selected.

9. The automatic testing method of claim 6, wherein, Step S44 comprises: Step S441, importing a test outline document to form a test requirement; Step S442, editing the test case; Step S443, test criterion editing; Step S444, test case set editing completion.

10. The automatic testing method of claim 9, wherein, In step S441, the test case is set for communication time, variable name, condition judgment, and compiling language selection mode.

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