Hardware-in-the-Loop Simulation Test Method for Electric Drive System Fault Injection

Abstract

The present invention discloses a hardware-in-the-loop simulation test method for electric drive system fault injection. The power battery model, driver model, and vehicle dynamics model are run to simulate the dynamic characteristics of the electric drive system. Under the control of the host computer, the power battery single-cell electrical fault mode configuration information is sent to the fault injection unit. The I / O signal electrical fault injection unit inputs the I / O signal fault configuration information into the port current simulation module under the control of the host computer. The fault will be detected by the test system under the action of the motor controller, and then enter the corresponding fault mode detection. The vehicle dynamics model calculates the vehicle speed at the next moment and sends it to the driver model, and the power battery model calculates the voltage information at the next moment and sends it to the motor model, and this cycle is executed accordingly. The present invention can simulate various fault states of the electric drive system to test and verify the working performance of the motor controller under various extreme working conditions.

Description

Technical Field

[0001] The present invention relates to the simulation and testing technology of the electric drive system for electric vehicles, and specifically relates to a hardware-in-the-loop simulation testing method for fault injection of the electric drive system. Background Art

[0002] With the gradual attention paid to energy and environmental issues, the development of the traditional automotive industry has been challenged. With the increasing maturity of new energy vehicle technologies, new energy vehicles have gradually gained a foothold in the automotive market. In recent years, with the increasing popularity of carbon peak and carbon neutrality, new energy vehicles have started to experience explosive growth. As a type of new energy vehicle, pure electric vehicles have become the leader of new energy vehicles due to their energy-saving characteristics. As one of the core components of electric vehicles, vehicle drive motors and controllers mainly affect many factors such as the driving range and overall vehicle performance of electric vehicles, and have always played an indispensable role in electric vehicles. Therefore, during the R & D process of electric vehicles, core components such as vehicle drive motors and controllers need to be tested multiple times from design to installation to ensure that they can meet the requirements of vehicle driving.

[0003] Hardware-in-the-loop simulation testing (HIL) is also known as semi-physical simulation. It is a simulation system that directly places the hardware of the part of the system to be simulated into the simulation loop. It not only makes up for many defects in pure digital simulation, improves the confidence level of the entire model, but also can greatly reduce the workload of programming. HIL is one of the commonly used testing methods for the core components of electric vehicles. The HIL system uses a real-time processor to run the simulation model to simulate the operating state of the controlled object, and is connected to the component under test through the I / O interface to conduct comprehensive and systematic tests on the component under test. The advantage of this simulation is that it realizes real-time data interaction between the simulation model and the actual system, making the verification process of the simulation results very intuitive and greatly shortening the product development cycle.

[0004] There are mainly three categories of HIL testing systems for vehicle drive motors and controllers: mechanical-level HIL systems, signal-level HIL systems, and power-level HIL systems.

[0005] Mechanical-level HIL system: That is, a physical controller + a physical motor are towed against a dynamometer. The main function of the dynamometer is to load the motor with a load simulating the actual working conditions for HIL testing. The advantage of the mechanical-level HIL system is that it can test the matching degree of the motor and the controller and the working performance of the motor and the controller under different working conditions. However, the obvious disadvantage of the mechanical-level HIL system is that it requires physical objects of the controller and the motor, which requires the experiment to be carried out in sufficient space and conditions, and at the same time, the operation of the motor will also cause noise pollution.

[0006] Signal-level HIL system: The signals of the controller control board are directly connected to the HIL system, and the rest of the system is all simulated by software. The signal-level HIL system mainly tests the hardware circuit of the control board and its internal control algorithm to check whether its structure can meet the established requirements. The advantage of the signal-level HIL system is that it has no physical motor, so it avoids the disadvantages of the mechanical-level HIL system during experiments. Moreover, the signal-level HIL system can simulate the fault states of the virtual motor, and then verify the controller's response to this fault. The disadvantage of the signal-level HIL system is that it cannot simulate the large current during operation, has poor reliability, and cannot verify the control performance of the controller.

[0007] Power-level HIL system: Connect the physical motor controller to the virtual motor at the power level, and test the performance of the motor controller under the vehicle working conditions by changing the load of the virtual motor. The virtual motor can achieve the same functions as the actual motor, and can work under different working conditions or even different fault states by setting parameters to test the control performance of the controller. The main advantage of the power-level HIL system is that the operation is relatively simple, and only the corresponding parameters need to be adjusted. The main disadvantage of the power-level HIL system is that most of the existing virtual motors are composed of a simple three-phase bridge + inductor. This structure can only simulate the fundamental wave current of the motor and cannot truly restore the ripple current of the motor, so it cannot truly reflect the control characteristics and performance of the motor controller. Summary of the Invention

[0008] The present invention provides a hardware-in-the-loop simulation test method for fault injection of an electric drive system, which can simulate various fault states of the electric drive system to test and verify the working performance of the motor controller under various extreme working conditions.

[0009] The technical solutions to solve the above technical problems are as follows:

[0010] A hardware-in-the-loop simulation test method for fault injection of an electric drive system, including a motor controller, a dynamic model of the electric drive system, a fault injection unit, and a host computer. The motor controller is electrically connected to the dynamic model of the electric drive system and the fault injection unit respectively, the host computer is electrically connected to the dynamic model of the electric drive system and the fault injection unit, and the dynamic model of the electric drive system is electrically connected to the fault injection unit, including the following steps:

[0011] A. A power battery model, a driver model, and a vehicle dynamics model are set in the dynamic model of the electric drive system. The power battery model, the driver model, and the vehicle dynamics model are run to simulate the dynamic characteristics of the electric drive system. The power battery model simulates the change of the battery voltage during driving, the driver model provides a torque command for the motor controller to be tested, and the vehicle dynamics model provides a load torque or speed constraint parameter for the power-level virtual motor;

[0012] B. Send the power battery single - cell electrical fault mode configuration information to the fault injection unit under the control of the host computer; the I / O signal electrical fault injection unit inputs the I / O signal fault configuration information into the port current simulation module under the control of the host computer, and the fault will be detected by the test system under the action of the motor controller, thus entering the corresponding fault mode detection;

[0013] C. The vehicle dynamics model calculates the vehicle speed at the next moment and sends it to the driver model, and the power battery model calculates the voltage information at the next moment and sends it to the motor model, and this cycle is executed accordingly.

[0014] Further, the fault mode detection includes the power battery single - cell voltage output short - circuit fault test and the power battery single - cell voltage output open - circuit fault test.

[0015] Further, the port current simulation module is used for the port current abnormal output test.

[0016] Further, in step A, a human - machine interface is also provided, and the data of the running power battery model, driver model, and vehicle dynamics model are recorded.

[0017] Further, the electric drive system dynamic model runs in the FPGA chip, and the fault injection unit runs in the CPU.

[0018] The advantages of the present invention are:

[0019] The in - the - loop simulation test method simulates various faults of the electric drive system through the fault injection unit, tests and verifies the motor controller under extreme working conditions, can accurately reflect the dynamic characteristics of the new energy vehicle electric drive system, simulate various fault states of the electric drive system, and test and verify the working performance of the motor controller under various extreme working conditions, which has an important supporting role in the design, development, and evaluation of the new energy vehicle motor controller. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is the system structure diagram of an in - the - loop simulation test system for electric drive system fault injection hardware of the present invention;

[0021] Figure 2 It is the host computer function structure diagram of an in - the - loop simulation test system for electric drive system fault injection hardware of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0022] The present invention will be further described below in conjunction with the drawings and the specific embodiments.

[0023] As Figure 1 and Figure 2As shown in the figure, the hardware-in-the-loop simulation test method for electric drive system fault injection of the present invention includes a motor controller, an electric drive system dynamic model, a fault injection unit, and a host computer. The motor controller is electrically connected to the electric drive system dynamic model and the fault injection unit respectively. The host computer is electrically connected to the electric drive system dynamic model and the fault injection unit. The electric drive system dynamic model is electrically connected to the fault injection unit. The electric drive system dynamic model runs in an FPGA chip, and the fault injection unit runs in a CPU. The in-the-loop simulation test is realized through the following steps:

[0024] A. A power battery model, a driver model, and a vehicle dynamics model are set in the electric drive system dynamic model. The power battery model, the driver model, and the vehicle dynamics model are run to simulate the dynamic characteristics of the electric drive system. The power battery model simulates the change of battery voltage during driving. The driver model provides a torque command for the motor controller under test. The vehicle dynamics model provides load torque or speed constraint parameters for the power stage virtual motor.

[0025] An inverter model, a resolver model, and a virtual motor real-time control system are also set in the electric drive system dynamic model. Among them, the virtual motor real-time control system mainly has two functions: a motor model algorithm and a current control algorithm.

[0026] In step A, a human-machine interface is also provided, and the data of running the power battery model, the driver model, and the vehicle dynamics model are recorded.

[0027] B. Under the control of the host computer, send the power battery single-cell electrical fault mode configuration information to the fault injection unit; that is, the fault injection unit is used to input the power battery single-cell electrical fault mode configuration information into the controller under test. The I / O signal electrical fault injection unit inputs the I / O signal fault configuration information into the port current simulation module under the control of the host computer. The port current simulation module is used for port current abnormal output test. The fault will be detected by the test system under the action of the motor controller, and then enter the corresponding fault mode detection. The fault mode detection includes power battery single-cell voltage output short-circuit fault test and power battery single-cell voltage output open-circuit fault test.

[0028] C. The vehicle dynamics model calculates the vehicle speed at the next moment and sends it to the driver model. The power battery model calculates the voltage information at the next moment and sends it to the motor model, and this cycle is executed.

[0029] The present invention simulates the dynamic response of the electric drive system under various working conditions through the electric drive system dynamic model. The host computer sends the electric drive system fault mode configuration information to the fault injection unit. The fault injection unit inputs the I / O signal fault configuration information into the port current simulation module, so that the electric drive system presents the corresponding fault state.

[0030] Finally, it should be noted that the above-described embodiments are only preferred embodiments of the present invention to illustrate the technical solutions of the present invention, rather than limiting it, let alone limiting the protection scope of the present invention; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements on some or all of the technical features; and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the protection scope of the claims.

Claims

1. A hardware-in-the-loop simulation test method for electric drive system fault injection, including a motor controller, an electric drive system dynamic model, a fault injection unit, and a host computer. The motor controller is electrically connected to the electric drive system dynamic model and the fault injection unit respectively, the host computer is electrically connected to the electric drive system dynamic model and the fault injection unit, and the electric drive system dynamic model is electrically connected to the fault injection unit, characterized in that, Including the following steps: A. Run the dynamic model of the electric drive system in the FPGA chip, and run the fault injection unit in the CPU; a power battery model, a driver model, and a vehicle dynamics model are set in the dynamic model of the electric drive system, and the power battery model, the driver model, and the vehicle dynamics model are run to simulate the dynamic characteristics of the electric drive system. The power battery model simulates the change of the battery voltage during driving, the driver model provides a torque command for the motor controller under test, and the vehicle dynamics model provides a load torque or speed constraint parameter for the power stage virtual motor; B. Under the control of the host computer, send the configuration information of the electrical fault mode of the power battery single cell to the fault injection unit and input it into the controller under test; the I / O signal electrical fault injection unit inputs the I / O signal fault configuration information into the port current simulation module under the control of the host computer for the abnormal output test of the port current; The faults will be detected by the test system under the action of the motor controller, and then enter the corresponding fault mode detection, and the fault mode detection includes the short-circuit fault test of the power battery single cell voltage output and the open-circuit fault test of the power battery single cell voltage output; C. The vehicle dynamics model calculates the vehicle speed at the next moment and sends it to the driver model, and the power battery model calculates the voltage information at the next moment and sends it to the motor model, and this cycle is executed accordingly.

2. The hardware-in-the-loop simulation test method for electric drive system fault injection according to claim 1, wherein In step A, a human-machine interface is also provided, and the data of running the power battery model, the driver model, and the vehicle dynamics model are recorded.

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