A method for developing a semi-physical simulation test system for a fuel cell controller

Abstract

The application relates to a kind of semi-physical simulation test system development methods for fuel cell controller, including fuel cell controlled object model, FCU-HIL interactive I / O electrical interface model library, HIL semi-physical simulation test environment software and hardware configuration development process.The application can simulate various working conditions and faults in the operation process of fuel cell, quickly test and verify control strategy, and improve the test efficiency of fuel cell control strategy and controller.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of fuel cell technology, and particularly relates to a development method of a semi-physical simulation test system for a fuel cell controller. BACKGROUND

[0002] A fuel cell is a complex dynamic system, and the control of its operating parameters such as inlet temperature, pressure, flow rate, humidity and the like has the characteristics of time variation, nonlinearity, hysteresis and strong coupling. A good control strategy / system is the core of stable operation, short response time, performance improvement and service life of a fuel cell, and is also the key to the development and commercialization of a fuel cell product.

[0003] A fuel cell controller (FCU) is the "brain" of a control system and is the carrier of all fuel cell control strategies. After the development of a fuel cell system control strategy, comprehensive functional testing, especially limit condition verification and fault injection testing, must be performed. If actual fuel cell test benches are used, many conditions are difficult to achieve, and high time and cost are required. If a hardware-in-the-loop (HIL) semi-physical simulation platform is used, various conditions, especially limit and fault conditions, can be tested, and the fuel cell control strategy can be quickly and effectively verified.

[0004] A fuel cell controller HIL semi-physical simulation system mainly includes a fuel cell controlled object model, an input / output (I / O) electrical interface model library, an operation interface (host computer) and a real-time target machine.

[0005] Compared with VCU, MCU and ECU controllers that have been developed to maturity, the HIL semi-physical simulation system for FCU is still in the initial development stage, and the development accuracy of each key link needs to be improved, mainly in the following aspects:

[0006] There is a lack of an I / O electrical interface model library specially for the FCU-HIL semi-physical simulation test system, so that the input / output interaction between the controlled object model and the FCU physical object is more efficient and simple;

[0007] The accuracy of the controlled object model for a fuel cell needs to be improved to better represent the operating state of the actual controlled object;

[0008] There is a lack of an experimental operation interface specially for the FCU-HIL semi-physical simulation test system, so that the test management and interaction process is more intuitive and convenient. SUMMARY

[0009] To solve the above technical problems, the object of the present application is to provide a semi-physical simulation test system development method for fuel cell controller.

[0010] To achieve the above object, the present application adopts the following technical solution:

[0011] A semi-physical simulation test system development method for fuel cell controller, comprising a fuel cell controller, a fuel cell system simulation model unit, an FCU-HIL interactive I / O electrical interface model unit, a real-time target machine, a hardware I / O board card, a fault injection unit, an auxiliary system (Balance of Plant, BOP) and sensor unit, and a HIL test system host computer, wherein the fuel cell controller is connected with the fault injection unit and the auxiliary system BOP and sensor unit, the fault injection unit and the auxiliary system BOP and sensor unit are connected with the real-time target machine through the hardware I / O board card, the real-time target machine is connected with the FCU-HIL interactive I / O electrical interface model unit, the FCU-HIL interactive I / O electrical interface model unit is connected with the fuel cell system simulation model unit, the output end of the fuel cell system simulation model unit is connected with the input end of the real-time target machine, and the fuel cell controller is connected with the HIL test system host computer.

[0012] The software and hardware configuration steps of the HIL test system,

[0013] Step 1: configuring the software of the HIL test system, comprising the following steps:

[0014] Step 1.1: building a fuel cell controlled object model based on Python, C language or Matlab according to the fuel cell analysis model, and performing parameter calibration and debugging check on the controlled object model;

[0015] Step 1.2: according to the electrical parameters of each auxiliary system BOP and sensor and the state of the controlled object model, the corresponding relationship between the input and output signals of the fuel cell controller FCU and the controlled object model and the signal conversion mode of each electrical component are sorted out, and the FCU-HIL electrical interactive I / O interface model is built based on Python, C or Matlab;

[0016] Step 1.3: sorting out all the test parameters and fault state parameters of the HIL system, and building an experimental management, fault injection and automatic test software host computer interface;

[0017] Step 1.4: completing the software configuration of the real-time target machine in the computer, and connecting the controlled object model in step 1.1 and the interface model in step 1.2 to the target machine in Python, C language or Matlab;

[0018] Step 1.5: download the controlled object model in step 1.1 and the interface model in step 1.2 into the real-time target machine through compiling in the compiling tool;

[0019] Step 2: complete the hardware configuration of the HIL test system, including the following steps:

[0020] Step 2.1: perform excitation test on all I / O interfaces of each signal board card of the HIL, and test whether each PIN pin can transmit and receive signals within the normal limit value;

[0021] Step 2.2: connect the input and output signal lines of each language according to the signal type and the corresponding board card channel of the electrical interface model to the corresponding PIN pin of each I / O signal board;

[0022] Step 3: after completing the software configuration in step 1 and the hardware configuration in step 2, control the HIL system through the experimental management software in step 1.3 to perform open-loop and closed-loop tests on the fuel cell controller FCU, and further debug and verify the electrical interface model and the controlled object model;

[0023] Step 4: perform functional and performance simulation tests on the fuel cell controller FCU on the HIL test system checked in step 3;

[0024] Step 5: determine whether fault simulation is needed according to the actual test requirements of the fuel cell controller FCU,

[0025] if yes, then connect a fault injection unit between the fuel cell controller FCU and the hardware board card and complete the fault simulation test of the fuel cell controller FCU by controlling the host computer,

[0026] if no, the functional and performance HIL simulation test of the fuel cell controller FCU is completed;

[0027] Step 6: complete the functional, performance, and fault simulation complete simulation test example of the fuel cell controller FCU according to steps 4 and 5, obtain all simulation test data, analyze the results, and write a simulation test example report;

[0028] Step 7: after step 6, the working condition simulation of the fuel cell controller FCU can be automatically tested by controlling the host computer through the automatic test software;

[0029] Step 8: evaluate the function and performance of the fuel cell controller FCU in combination with the simulation test output and analysis results.

[0030] Preferably, in the development method of the semi-physical simulation test system for the fuel cell controller, the test parameters of the HIL system in step 1.3 include the control quantity of the fuel cell controller FCU, the state parameters of each auxiliary system BOP and sensor, etc.

[0031] Preferably, the method for developing a semi-physical simulation test system for a fuel cell controller comprises the following steps for constructing a model of a controlled object of a fuel cell system:

[0032] Step 1: based on actual physical parameters of fuel cell anode gas and cathode gas, a physical property library of anode reaction gas and cathode reaction gas is established;

[0033] Step 2: based on actual performance parameters and pipeline structure of a hydrogen supply auxiliary system BOP of the fuel cell system, a model of an anode-side hydrogen supply system is built;

[0034] Step 3: based on actual performance parameters and pipeline structure of an air supply auxiliary system BOP of the fuel cell system, a model of a cathode-side air supply system is built;

[0035] Step 4: based on actual performance parameters and pipeline structure of a water supply auxiliary system BOP of the fuel cell system, a model of a temperature management cooling water supply system is built;

[0036] Step 5: based on actual electrical parameters and experimental power generation performance data of a DCDC, a DCDC power load model is built;

[0037] Step 6: based on actual structure, reaction mechanism and physical and chemical performance parameters of a fuel cell / stack, a fuel cell / stack model is built;

[0038] Step 7: the anode / cathode reaction gas physical property library established in Step 1 is taken as an input source term of the anode / cathode-side hydrogen supply system model in Steps 2 and 3, and the total pressure of the anode / cathode flow field and the pressure of each component gas of the anode / cathode are calculated by simultaneous equations, the cooling liquid in / out stack temperature term calculated by simultaneous calculation of the temperature management cooling water supply system model in Step 4 and the load current simulated by the DCDC power load model in Step 5 are taken as input terms of the fuel cell / stack model in Step 6, and the running voltage / power of the fuel cell system is calculated as an output;

[0039] Step 8: by inputting actual test working condition input conditions and electrical performance data, the controlled object model is parameter calibrated and debugged and checked, and the accuracy of the controlled object model is improved.

[0040] Preferably, the semi-physical simulation test system for a fuel cell controller, the actual physical parameters of the anode gas and the cathode gas of the fuel cell include: flow rate, pressure, mass fraction of each component, molar mass, molar fraction and gas partial pressure;

[0041] The anode-side hydrogen supply system model includes a hydrogen inlet proportional valve model, an anode inlet manifold model, an anode gas flow field model, an anode exhaust valve model, an anode water exhaust valve model and a hydrogen circulation pump model;

[0042] The cathode side air supply system model comprises an air compressor model, a intercooler model, a humidifier model, a stop valve model, a cathode inlet manifold model, a cathode flow field model, a cathode exhaust manifold model and a back pressure valve model;

[0043] The temperature management cooling water supply system model comprises a cooling water circulating pump model, a heating PTC model, a cooling fan model, a thermostat model, an intercooler model and a stack cooling model;

[0044] The actual structure, reaction mechanism and physical and chemical performance parameters of the fuel cell / stack are used to build a fuel cell / stack model, which comprises:

[0045] (1) an anode side model simulating anode fuel gas diffusion transmission, catalytic adsorption and electrochemical reaction;

[0046] (2) an electrolyte membrane model simulating electrolyte membrane ion transmission, water cross-membrane transmission and nitrogen cross-membrane transmission;

[0047] (3) a cathode side model simulating cathode fuel gas diffusion transmission, catalytic adsorption and electrochemical reaction.

[0048] Preferably, the development method of the semi-physical simulation test system for the fuel cell controller comprises the following steps of constructing the FCU-HIL interactive I / O electrical interface model library:

[0049] 1. Based on the I / O signal types and conversion methods of the controlled electrical components of each subsystem auxiliary system BOP, an interface conversion model is built and each electrical component is packaged into a separate module;

[0050] 2. Based on the signal types and conversion methods of various sensors, an interface conversion model is built and each type of sensor is packaged into a separate module;

[0051] 3. Based on the CAN drive module and the CAN communication message information of each electrical component, the CAN message unpacking / packing module is configured, and the corresponding signal I / O module is configured based on the digital board card, analog board card, resistance board card and current board card drive module;

[0052] 4. According to the I / O signal types of each electrical component and sensor, the matching connection with the corresponding board card drive module channel is completed.

[0053] Preferably, the development method of the semi-physical simulation test system for the fuel cell controller comprises the following steps of constructing the FCU-HIL interactive I / O electrical interface model library:

[0054] (1) an anode hydrogen supply road electrical interface library of an hydrogen inlet proportional valve electrical conversion model, a hydrogen circulating pump electrical conversion model, an exhaust valve electrical conversion model and a drain valve electrical conversion model;

[0055] (2) the cathode hydrogen supply path electrical interface library of the air compressor electrical conversion model, the stop valve electrical conversion model and the back pressure valve electrical conversion model;

[0056] (3) the cathode hydrogen supply path electrical interface library of the water pump electrical conversion model, the heating PTC electrical conversion model, the fan electrical conversion model and the radiator electrical conversion model.

[0057] Preferably, the sensor includes a temperature sensor electrical conversion model, a pressure sensor electrical conversion model, a flow sensor electrical conversion model and a concentration sensor electrical conversion model.

[0058] By the above scheme, the present application has at least the following advantages:

[0059] 1. The present application uses a semi-physical simulation test system to test the fuel cell controller FCU, thereby improving the test efficiency of the fuel cell control strategy and the controller.

[0060] 2. The construction of the fuel cell controlled object model and the FCU-HIL interactive I / O electrical interface model library in the present application perfects the main modules of the FCU-HIL simulation test system.

[0061] 3. The fuel cell controller HIL test based on the semi-physical simulation platform of the present application enhances the function implementation, stability and matching with the controlled object of the fuel cell controller, and improves the development efficiency of the fuel cell controller FCU.

[0062] 4. The test through the extreme working condition and fault injection of the present application reduces the actual test time, cost, risk and shortens the product development cycle.

[0063] The above description is only a summary of the technical scheme of the present application, in order to more clearly understand the technical means of the present application, and can be implemented according to the content of the specification, as follows. BRIEF DESCRIPTION OF DRAWINGS

[0064] In order to more clearly illustrate the technical scheme of the embodiments of the present application, the following will briefly introduce the drawings needed to be used in the embodiments, it should be understood that the following drawings only show some embodiments of the present application, therefore should not be regarded as a limitation on the scope, for those skilled in the art, without creative labor, can also obtain other related drawings according to these drawings.

[0065] Figure 1 is the FCU-HIL simulation test system architecture diagram of the present application;

[0066] Figure 2This is a flowchart of the development process of the FCU-HIL simulation test system of the present invention;

[0067] Figure 3 This is a schematic diagram of the controlled object model of the fuel cell system of the present invention;

[0068] Figure 4 This is a schematic diagram of the FCU-HIL interactive I / O electrical interface model library of the present invention. Detailed Implementation

[0069] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0070] Example

[0071] like Figure 1 As shown, a method for developing a hardware-in-the-loop (HIL) simulation test system for a fuel cell controller includes a fuel cell controller 1, a fuel cell system (controlled object) simulation model unit 2, an FCU-HIL interactive I / O electrical interface model unit 3, a real-time target machine 4, a hardware I / O board 5, a fault injection unit 6, an auxiliary system BOP and sensor unit 7, and a HIL test system host computer 8. The fuel cell controller 1 is interactively connected to the fault injection unit 6 and the auxiliary system BOP and sensor unit 7. The fault injection unit 6 and the auxiliary system BOP and sensor unit 7 are interactively connected to the real-time target machine 4 through the hardware I / O board 5. The real-time target machine 4 is interactively connected to the FCU-HIL interactive I / O electrical interface model unit 3. The FCU-HIL interactive I / O electrical interface model unit 3 is interactively connected to the fuel cell system simulation model unit 2. The output terminal of the fuel cell system simulation model unit 2 is connected to the input terminal of the real-time target machine 4. The fuel cell controller 1 is interactively connected to the HIL test system host computer 8.

[0072] in,

[0073] The simulation model of the fuel cell system (controlled object) includes: stack model, anode-side hydrogen supply system model, cathode-side air supply system model, temperature-managed cooling water supply system model, and DC-DC power load model;

[0074] FCU-HIL interactive I / O electrical interface model, including interface conversion models of BOP electrical components of various controlled auxiliary systems, electrical interface conversion models of various sensors, CAN message unpacking / packing module, digital / analog / resistance / current signal I / O module;

[0075] Real-time target machine running simulation calculation;

[0076] Hardware I / O board, including: CAN card, digital board, analog board, resistance board, current board, etc.

[0077] HIL test system host computer, including: experiment management software, fault injection software, automatic test software, etc.

[0078] Auxiliary system BOP and sensor unit, including fuel cell controller FCU, fault injection unit, auxiliary system BOP / sensor, etc.

[0079] As shown in Figure 2 , the software and hardware configuration of the HIL test system,

[0080] Step 1: Configure the software configuration of the HIL test system, including the following steps:

[0081] Step 1.1: According to the fuel cell analysis model, build the fuel cell controlled module based on Python, C language or Matlab, and perform parameter calibration and debugging verification on the controlled module;

[0082] Step 1.2: According to the electrical parameters of each auxiliary system (Balance of Plant, BOP) and sensor and the state of the controlled object model, sort out the corresponding relationship between the input and output signals of the fuel cell controller FCU and the controlled object model and the signal conversion method of each electrical component, and build the FCU-HIL electrical interaction I / O interface model based on Python, C language or Matlab;

[0083] Step 1.3: Sort out all test parameters and fault state parameters of the HIL system, and build the experiment management, fault injection and automatic test software host computer interface;

[0084] Step 1.4: Complete the software configuration of the real-time target machine in the computer, and connect the controlled object model in step 1.1 and the interface model in step 1.2 to the target machine in Python, C language or Matlab;

[0085] Step 1.5: In the compilation tool, download the controlled object model in step 1.1 and the interface model in step 1.2 to the real-time target machine through compilation;

[0086] Step 2: Complete the hardware configuration of the HIL test system, including the following steps:

[0087] Step 2.1: Test all I / O interfaces of HIL signal board, test whether each PIN pin can receive and transmit signals within the normal limit value, and debug or replace the board for unqualified ones;

[0088] Step 2.2: According to the signal type and the electrical interface model to which each input and output signal line of the fuel cell controller FCU belongs, each I / O signal board is connected to the corresponding PIN pin of the card channel;

[0089] Step 3: After completing the software configuration of step 1 and the hardware configuration of step 2, the HIL system is controlled by the experimental management software in step 1.3 to perform open-loop and closed-loop tests of the fuel cell controller FCU, and further debugging and verification of the electrical interface model and the controlled object model are performed;

[0090] Step 4: Perform functional and performance simulation tests of the fuel cell controller FCU on the HIL test system after step 3;

[0091] Step 5: Determine whether fault simulation is needed according to the actual test requirements of the fuel cell controller FCU,

[0092] If so, a fault injection unit is connected between the fuel cell controller FCU and the hardware card, and the fuel cell controller FCU fault simulation test is completed by controlling the host computer,

[0093] If not, the functional and performance HIL simulation test of the fuel cell controller FCU has been completed;

[0094] Step 6: Complete the functional, performance, and fault simulation complete simulation test example of the fuel cell controller FCU according to steps 4 and 5, obtain all simulation test data, analyze the results, and write a simulation test example report;

[0095] Step 7: After step 6, the working condition simulation of the fuel cell controller FCU can be automatically tested by the automatic test software host computer;

[0096] Step 8: Based on the simulation test output and analysis results, the function and performance of the fuel cell controller FCU are evaluated.

[0097] In the present application, all test parameters of the HIL system in step 1.3 include the fuel cell controller FCU control quantity, the state parameters of each auxiliary system BOP and sensor, etc.

[0098] As shown in Figure 3 , for the construction of the fuel cell system controlled object model, the following steps are included:

[0099] Step 1: Based on the actual physical parameters of the fuel cell anode gas and cathode gas, including flow rate, pressure, mass fraction of each component, molar mass, molar fraction, gas partial pressure, etc., a physical property library of anode reaction gas and cathode reaction gas is established;

[0100] Step 2: Based on the actual performance parameters and pipeline structure of the hydrogen supply system BOP of the fuel cell system, an anode-side hydrogen supply system model is established, including a hydrogen inlet proportional valve model, an anode inlet manifold model, an anode gas flow field model, an anode exhaust valve model, an anode drain valve model, and a hydrogen circulation pump model;

[0101] Step 3: Based on the actual performance parameters and pipeline structure of the air supply system BOP of the fuel cell system, a cathode-side air supply system model is established, including a compressor model, an intercooler (hot fluid) model, a humidifier model, a stop valve model, a cathode inlet manifold model, a cathode flow field model, a cathode exhaust manifold model, and a back pressure valve model;

[0102] Step 4: Based on the actual performance parameters and pipeline structure of the water supply system BOP of the fuel cell system, a temperature management cooling water supply system model is established, including a cooling water circulation pump model, a heating PTC model, a cooling fan model, a thermostat model, an intercooler (cold fluid) model, and a stack cooling model;

[0103] Step 5: Based on the actual electrical parameters and experimental power generation performance data of the DCDC, a DCDC power load model is established;

[0104] Step 6: Based on the actual structure, reaction mechanism, and physicochemical performance parameters of the fuel cell / stack, a fuel cell / stack model is established, including:

[0105] (1) an anode-side model simulating anode fuel gas diffusion transmission, catalytic adsorption, and electrochemical reaction;

[0106] (2) an electrolyte membrane model simulating electrolyte membrane ion transmission, water cross-membrane transmission, and nitrogen cross-membrane transmission;

[0107] (3) a cathode-side model simulating cathode fuel gas diffusion transmission, catalytic adsorption, and electrochemical reaction;

[0108] Step 7: The anode / cathode reaction gas property library established in Step 1 is used as the input source term of the anode / cathode-side hydrogen supply system model in Steps 2 and 3, and the total pressure of the anode / cathode flow field and the pressure of each component gas are calculated by simultaneous equations. The cooling liquid in / out stack temperature term obtained by the temperature management cooling water supply system model in Step 4 and the load current simulated by the DCDC power load model in Step 5 are used as the input term of the fuel cell / stack model in Step 6 to calculate the output fuel cell system operating voltage / power;

[0109] Step 8: By inputting the actual test operating conditions and electrical performance data, the parameter calibration and debugging of the controlled object model are performed to improve the accuracy of the controlled object model.

[0110] For example, Figure 4As shown, the construction of the FCU-HIL interaction I / O electrical interface model library includes the following steps:

[0111] 1. Build the interface conversion model based on the I / O signal type and conversion mode of each subsystem auxiliary system BOP controlled electrical component and encapsulate each electrical component as a separate module, including:

[0112] (1) Anode hydrogen supply path electrical interface library of hydrogen inlet proportional valve electrical conversion model, hydrogen circulating pump electrical conversion model, exhaust valve electrical conversion model, and water discharge valve electrical conversion model;

[0113] (2) Cathode hydrogen supply path electrical interface library of air compressor electrical conversion model, stop valve electrical conversion model, and back pressure valve electrical conversion model;

[0114] (3) Cathode hydrogen supply path electrical interface library of water pump electrical conversion model, heating PTC electrical conversion model, fan electrical conversion model, and radiator electrical conversion model;

[0115] 2. Build the interface conversion model based on the signal type and conversion mode of each type of sensor and encapsulate each type of sensor as a separate module, including: temperature sensor electrical conversion model, pressure sensor electrical conversion model, flow sensor electrical conversion model, and concentration sensor electrical conversion model;

[0116] 3. Complete the configuration of CAN message unpacking / packing modules based on CAN drive modules and CAN communication message information of each electrical component, and complete the configuration of corresponding signal I / O modules based on digital board card, analog board card, resistance board card, and current board card drive modules;

[0117] 4. Complete the matching connection with the corresponding board card drive module channel according to the I / O signal type of each electrical component and sensor.

[0118] Therefore, the following detailed description of embodiments of the application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely represents selected embodiments of the application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor are within the scope of protection of the present application.

[0119] It should be noted that: similar reference numbers and letters represent similar items in the following drawings, therefore, once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings.

[0120] In the description of the present application, it should be noted that the terms "vertical", "horizontal", "inner", "outer", and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship in which the product of the application is usually placed, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application. In addition, the terms "first", "second", and the like are only used to distinguish the description and cannot be understood as indicating or implying relative importance.

[0121] In addition, the terms "horizontal", "vertical", and the like do not mean that the components must be absolutely horizontal or vertical, but can be slightly inclined. For example, "horizontal" only means that its direction is more horizontal relative to "vertical", and does not mean that the structure must be completely horizontal, but can be slightly inclined.

[0122] In the description of the present application, it should be noted that unless otherwise explicitly specified and limited, the terms "provided", "mounted", "connected", "connected" should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium; it can be the communication inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0123] The above is only the preferred embodiment of the present application, and is not intended to limit the present application. It should be noted that for those skilled in the art, without departing from the technical principles of the present application, a number of improvements and modifications can be made, and these improvements and modifications should be considered as the protection scope of the present application.

Claims

1. A method for developing a hardware-in-the-loop simulation test system for a fuel cell controller, comprising a fuel cell controller (1), characterized in that: It also includes a fuel cell system simulation model unit (2), an FCU-HIL interactive I / O electrical interface model unit (3), a real-time target machine (4), a hardware I / O board (5), a fault injection unit (6), an auxiliary system BOP and sensor unit (7), and a HIL test system host computer (8). The fuel cell controller (1) is interactively connected to the fault injection unit (6) and the auxiliary system BOP and sensor unit (7). The fault injection unit (6) and the auxiliary system BOP and sensor unit (7) are interactively connected to the real-time target machine (4) through the hardware I / O board (5). The real-time target machine (4) is interactively connected to the FCU-HIL interactive I / O electrical interface model unit (3). The FCU-HIL interactive I / O electrical interface model unit (3) is interactively connected to the fuel cell system simulation model unit (2). The output end of the fuel cell system simulation model unit (2) is connected to the input end of the real-time target machine (4). The fuel cell controller (1) is interactively connected to the HIL test system host computer (8). The software and hardware configuration steps that constitute the HIL test system Step 1: Configure the HIL test system software, including the following steps: Step 1.1: Based on the fuel cell analytical model, build a fuel cell controlled object model using Python, C, or Matlab, and perform parameter calibration and debugging verification on the controlled object model; Step 1.2: Based on the BOP of each auxiliary system, the electrical parameters of the sensors, and the state of the controlled object model, sort out the correspondence between the input and output signals of the fuel cell controller (FCU) and the controlled object model, as well as the signal conversion methods of each electrical component, and build the FCU-HIL electrical interaction I / O interface model based on Python, C language, or Matlab; Step 1.3: Organize all test parameters and fault status parameters of the HIL system, and build the host computer interface for experiment management, fault injection, and automatic testing software; Step 1.4: Complete the software configuration of the real-time target machine in the computer, and connect the controlled object model in Step 1.1 and the interface model in Step 1.2 to the target machine in Python, C or Matlab; Step 1.5: Compile and download the controlled object model from Step 1.1 and the interface model from Step 1.2 into the real-time target machine using the compilation tool; Step 2: Complete the hardware configuration of the HIL test system, including the following steps: Step 2.1: Perform stimulus tests on all I / O interfaces of each signal board in HIL to test whether each pin can send and receive signals within the normal limits; Step 2.2: Connect each input and output signal line of the fuel cell controller (FCU) to the corresponding pin of each I / O signal board according to its signal type and electrical interface model. Step 3: After completing the software configuration in Step 1 and the hardware configuration in Step 2, use the host computer of the experimental management software in Step 1.3 to control the HIL system to perform open-loop and closed-loop tests of the fuel cell controller FCU, and further debug and verify the electrical interface model and the controlled object model. Step 4: Perform functional and performance simulation tests on the fuel cell controller (FCU) on the HIL test system verified in Step 3; Step 5: Determine whether fault simulation is necessary based on the actual testing requirements of the fuel cell controller (FCU). If so, a fault injection unit is connected between the fuel cell controller (FCU) and the hardware board, and the host computer is used to complete the fuel cell controller (FCU) fault simulation test. If not, then the HIL simulation test of the fuel cell controller (FCU) function and performance has been completed; Step 6: Based on Steps 4 and 5, complete the full simulation test case of the fuel cell controller (FCU) function, performance, and fault simulation, obtain all simulation test data, analyze the results, and write a simulation test case report; Step 7: After step 6, the operating condition simulation test of the fuel cell controller (FCU) can be automatically performed by controlling the host computer of the automatic test software. Step 8: Evaluate the function and performance of the fuel cell controller (FCU) by combining the simulation test output and analysis results.

2. The development method of a hardware-in-the-loop simulation test system for a fuel cell controller according to claim 1, characterized in that: In step 1.3, all test parameters of the HIL system include the control input of the fuel cell controller (FCU), the BOP of each auxiliary system, and the status parameters of the sensors.

3. A method for developing a hardware-in-the-loop simulation testing system for a fuel cell controller according to claim 1 or 2, characterized in that: The construction of the controlled object model for a fuel cell system includes the following steps: Step 1: Based on the actual physical property parameters of the anode gas and cathode gas in the fuel cell, establish a physical property library for the anode reactant gas and cathode reactant gas; Step 2: Based on the actual performance parameters and pipeline structure of the BOP (Balance of Plant) of the hydrogen supply circuit auxiliary system of the fuel cell system, build a model of the anode-side hydrogen supply system; Step 3: Based on the actual performance parameters and pipeline structure of the BOP (Breakpoint Operator) of the fuel cell system's air supply system, build a model of the cathode-side air supply system; Step 4: Based on the actual performance parameters and pipeline structure of the BOP (Balance of Plant) auxiliary system of the fuel cell system water supply circuit, build a model of the temperature management cooling water supply system; Step 5: Build a DC-DC power load model based on the actual electrical parameters of the DC-DC converter and the experimentally measured power generation performance data; Step 6: Build a fuel cell / stack model based on the actual structure, reaction mechanism, and physicochemical performance parameters of the fuel cell / stack; Step 7: Use the anode / cathode reactive gas property library established in Step 1 as the input source term of the anode / cathode side hydrogen supply system model in Step 2 and Step 3. The total pressure of the anode / cathode flow field and the pressure of each component gas in the anode / cathode can be obtained by solving the simultaneous equations. Combined with the coolant inlet / outlet temperature term obtained by the temperature management cooling water supply system model in Step 4 and the load current obtained by the DC-DC power load model in Step 5, the fuel cell / stack model input term is used to calculate the output fuel cell system operating voltage / power. Step 8: By inputting actual test conditions and electrical performance data, perform parameter calibration and debugging of the controlled object model to improve the accuracy of the controlled object model.

4. The development method of a hardware-in-the-loop simulation test system for a fuel cell controller according to claim 3, characterized in that: The actual physical properties of the battery anode and cathode gases include: flow rate, pressure, mass fraction of each component, molar mass, molar fraction, and partial pressure of the gas. The anode-side hydrogen supply system model includes a hydrogen inlet proportional valve model, an anode inlet manifold model, an anode gas flow field model, an anode exhaust valve model, an anode drain valve model, and a hydrogen circulation pump model. The cathode-side air supply system model includes an air compressor model, an intercooler model, a humidifier model, a shut-off valve model, a cathode intake manifold model, a cathode flow field model, a cathode exhaust manifold model, and a back pressure valve model. The temperature management cooling water supply system model includes a cooling water circulation pump model, a heating PTC model, a cooling fan model, a thermostat model, an intercooler model, and a fuel cell stack heat dissipation model; The actual structure, reaction mechanism, and physicochemical performance parameters of fuel cells / stacks are used to build fuel cell / stack models, including: (1) An anode-side model simulating anode fuel gas diffusion transport, catalytic adsorption, and electrochemical reactions; (2) Electrolyte membrane models for ion transport, water transmembrane transport, and nitrogen transmembrane transport in the electrolyte membrane; (3) A cathode-side model simulating the diffusion and transport of fuel gas, catalytic adsorption, and electrochemical reaction of the cathode.

5. A method for developing a hardware-in-the-loop simulation test system for a fuel cell controller according to claim 1 or 2, characterized in that: The method for constructing the FCU-HIL interactive I / O electrical interface model library includes the following steps:

1. Based on the I / O signal types and conversion methods of the controlled electrical components in the BOP of each subsystem auxiliary system, an interface conversion model is built and each electrical component is encapsulated as a separate module; 2. Build an interface conversion model based on the signal types and conversion methods of various sensors, and encapsulate each type of sensor into a separate module; 3. Based on the CAN driver module and the CAN communication message information of each electrical component, complete the configuration of the CAN message unpacking / packing module; based on the digital board, analog board, resistor board, and current board driver modules, complete the configuration of the corresponding signal I / O modules.

4. Based on the I / O signal types of each electrical component and sensor, complete the matching connection with the corresponding board driver module channel.

6. The development method of a hardware-in-the-loop simulation test system for a fuel cell controller according to claim 5, characterized in that: Interface conversion models include (1) Electrical interface library for the anode hydrogen supply circuit of the electrical conversion model of the hydrogen inlet proportional valve, the electrical conversion model of the hydrogen circulation pump, the electrical conversion model of the exhaust valve, and the electrical conversion model of the drain valve; (2) Electrical interface library for the cathode hydrogen supply circuit of the air compressor electrical conversion model, the shut-off valve electrical conversion model, and the back pressure valve electrical conversion model; (3) Electrical interface library for the cathode hydrogen supply circuit of the water pump electrical conversion model, heating PTC electrical conversion model, fan electrical conversion model and radiator electrical conversion model.

7. The development method of a hardware-in-the-loop simulation test system for a fuel cell controller according to claim 5, characterized in that: The sensors include: Electrical conversion models for temperature sensors, pressure sensors, flow sensors, and concentration sensors.

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