A whole vehicle simulation system based on VTB virtual test bench

Abstract

The application provides a whole vehicle simulation system based on a VTB virtual bench, which comprises a driver simulator, a whole vehicle controller, a host computer and a VTB virtual bench; the driver simulator converts driver intention into whole vehicle steering wheel steering, throttle and brake signals; the steering and rotation signals are sent to the host computer, and the throttle and brake signals are transmitted to the whole vehicle controller; the whole vehicle controller generates motor torque signals according to the throttle and brake signals; the electronic brake unit in the VTB virtual bench calculates motor feedback torque signals in real time under brake working conditions according to the brake signals and vehicle speed signals, and sends the signals to a whole vehicle power system model; the whole vehicle power system model calculates half shaft torque at the rear end of a gearbox in real time according to the motor torque signals and the motor feedback torque signals; the host computer receives the half shaft torque at the rear end of the gearbox in real time, and calculates vehicle body posture and vehicle speed in real time. The application is optimized by online calibration according to the performance characteristics of each component, and forms a simulation and calibration data closed loop.

Description

Technical Field

[0001] This invention belongs to the field of whole vehicle simulation technology, and specifically relates to a whole vehicle simulation system based on a VTB virtual test bench. Background Technology

[0002] New energy vehicles refer to automobiles that use unconventional vehicle fuels as their power source (or use conventional vehicle fuels but employ new onboard power devices), integrating advanced technologies in vehicle power control and drive systems to create vehicles with advanced technical principles, new technologies, and new structures. New energy vehicles include pure electric vehicles, range-extended electric vehicles, hybrid electric vehicles, fuel cell electric vehicles, and hydrogen engine vehicles. New energy vehicles are a hot topic in the automotive industry. With increasing public awareness of environmental protection, new energy vehicles have experienced rapid development.

[0003] The main pain point of pure electric vehicle technology is its short driving range, and the solutions primarily involve increasing battery capacity and reducing energy consumption. For new energy commercial vehicles, the biggest industry pain point is currently the driving range issue, and the solutions mainly focus on two aspects: increasing battery capacity and reducing energy consumption. Increasing battery capacity directly increases the vehicle's weight and purchase cost, and also presents challenges in terms of layout space. Given the lack of significant breakthroughs in power battery technology and the supply chain, improving the overall vehicle's economic efficiency is currently the primary issue facing the industry. Verifying and improving vehicle economic efficiency often requires substantial time, money, and manpower; therefore, indoor economic simulation methods are becoming increasingly important. Summary of the Invention

[0004] To address the aforementioned technical issues, this invention proposes a vehicle simulation system based on a VTB virtual test bench, which achieves optimal performance for the entire vehicle and its components, and realizes a data closed loop for vehicle performance simulation and parameter optimization calibration.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A vehicle simulation system based on a VTB virtual test bench includes a driver simulator, a vehicle controller, a host computer, and a VTB virtual test bench.

[0007] The driver simulator is used to convert the driver's intentions into steering wheel signals, accelerator signals and braking signals for the whole vehicle; and to send the steering signals and steering signals to the host computer, and to transmit the accelerator signals and braking signals to the vehicle controller;

[0008] The vehicle controller generates a motor torque signal based on the throttle signal and the braking signal; and collects the braking torque signal of the electronic braking unit in the VTB virtual test bench to achieve interlocking of the motor torque signal and the braking torque signal.

[0009] The electronic braking unit in the VTB virtual test bench calculates the motor feedback torque signal under braking conditions in real time based on the braking signal and vehicle speed signal; and sends the motor feedback torque signal to the vehicle powertrain model; the vehicle powertrain model calculates the torque of the rear half-shaft of the transmission in real time based on the motor torque signal and the motor feedback torque signal.

[0010] The host computer receives the torque of the rear half-shaft of the gearbox in real time, and calculates the vehicle posture and speed in real time based on the real scene model and the vehicle residual model preset in the host computer.

[0011] Furthermore, the simulation system also includes a closed-loop control system for the whole vehicle, which is achieved by manipulating a driver simulator to change the vehicle speed and attitude in real time according to the vehicle posture and speed displayed on the host computer.

[0012] Furthermore, the driver simulator is communicatively connected to the vehicle controller and the host computer; the VTB virtual test bench is communicatively connected to the bus analysis unit and the vehicle controller; and the host computer is also communicatively connected to the bus analysis unit.

[0013] Furthermore, the real-time reception of the torque of the rear half-shaft of the gearbox by the host computer specifically means that the host computer receives the torque of the rear half-shaft of the gearbox through the bus analysis unit;

[0014] The process of calculating the vehicle's attitude and speed in real time based on the pre-set real-scene model and residual vehicle model in the host computer includes: calculating wheel torque based on the motor torque value and power chain transmission; calculating wheel resistance based on the ABC coefficient; and calculating the vehicle's acceleration / deceleration state and speed information based on the difference between wheel torque and wheel resistance.

[0015] Furthermore, the process by which the vehicle controller generates a motor torque signal based on the throttle signal and the braking signal includes: the vehicle controller using the throttle pedal opening to perform a MAP lookup table to obtain the corresponding torque value.

[0016] Furthermore, the process of interlocking the motor torque signal and the braking torque signal includes: when the electronic braking unit collects the braking torque signal, it issues a negative torque braking signal; the negative torque has the highest priority, and even if the accelerator is pressed deeply, the motor drive torque request is still 0, thus achieving the interlocking of the motor torque signal and the braking torque signal.

[0017] Furthermore, the process by which the vehicle powertrain model calculates the torque of the rear half-shaft of the transmission in real time based on the motor torque signal and the motor feedback torque signal includes: the vehicle controller multiplies the motor drive torque value or motor braking torque value by the gear ratio and efficiency value of the transmission in the current gear, and then divides by 2 to obtain the torque value of the rear half-shaft of the transmission.

[0018] Furthermore, the vehicle controller acquires signals from the vehicle thermal management model in the VTB virtual test bench to generate start / stop signals for each accessory;

[0019] The vehicle thermal management model in the VTB virtual test bench calculates the temperature of each power system and the power of each accessory based on the power information of each component in the power system model, the vehicle speed, and the start / stop signals.

[0020] Furthermore, the electronic braking unit in the VTB virtual test bench calculates the mechanical braking torque signal under braking conditions in real time based on the braking signal and vehicle speed signal, and sends the mechanical braking torque signal to the host computer.

[0021] The vehicle powertrain model receives vehicle speed, body posture, motor feedback torque signal, mechanical braking torque signal and power of each accessory through the bus analysis unit, and calculates motor energy consumption, battery energy consumption and vehicle energy consumption in real time.

[0022] Furthermore, the system also includes a calibration unit, which is communicatively connected to the vehicle controller. The calibration unit is used to adjust the vehicle or component parameters in the vehicle controller when the overall vehicle performance or the performance of each component does not meet expectations, so as to optimize the overall vehicle performance or the performance of each component.

[0023] The effects described in the invention are merely those of the embodiments, and not all the effects of the invention. One of the above technical solutions has the following advantages or beneficial effects:

[0024] This invention proposes a vehicle simulation system based on a VTB virtual test bench, comprising a driver simulator, a vehicle controller, a host computer, and a VTB virtual test bench. The driver simulator converts the driver's intentions into steering wheel signals, throttle signals, and braking signals; and sends the steering and steering signals to the host computer, while transmitting the throttle and braking signals to the vehicle controller. The vehicle controller generates motor torque signals based on the throttle and braking signals; and acquires braking torque signals from the electronic braking unit in the VTB virtual test bench, achieving interlocking between the motor torque signals and braking torque signals. The electronic braking unit in the VTB virtual test bench calculates the motor feedback torque signal under braking conditions in real time based on the braking signal and vehicle speed signal; and sends the motor feedback torque signal to the vehicle powertrain model. The vehicle powertrain model calculates the transmission rear half-shaft torque in real time based on the motor torque signal and the motor feedback torque signal. The host computer receives the transmission rear half-shaft torque in real time and calculates the vehicle body posture and speed in real time based on the pre-set real-scene model and vehicle residual model within the host computer. This invention takes into account the vehicle's power system and thermal management system, and adjusts the vehicle's driving status in real time according to environmental road factors and driver intentions. It calculates and evaluates the performance of each component, vehicle energy consumption, and the impact of human and environmental factors on the vehicle's economy in real time. It also performs online calibration and optimization based on the performance characteristics of each component, forming a closed loop of simulation and calibration data. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of a vehicle simulation system based on a VTB virtual test bench, as proposed in Embodiment 1 of the present invention.

[0026] Figure 2 This is a schematic diagram of the connection of a vehicle simulation system based on a VTB virtual test bench, as proposed in Embodiment 1 of the present invention. Detailed Implementation

[0027] To clearly illustrate the technical features of this solution, the invention will be described in detail below through specific embodiments and in conjunction with the accompanying drawings. The following disclosure provides many different embodiments or examples for implementing different structures of the invention. To simplify the disclosure of the invention, components and arrangements of specific examples are described below. Furthermore, reference numerals and / or letters may be repeated in different examples. This repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed. It should be noted that the components illustrated in the drawings are not necessarily drawn to scale. Descriptions of well-known components, processing techniques, and processes are omitted in this invention to avoid unnecessarily limiting the invention.

[0028] Example 1

[0029] The present invention provides a vehicle simulation system based on a VTB virtual test bench, which takes into account the vehicle's power system, thermal management system, driver human influence, and real environmental factors for vehicle economic simulation and calibration.

[0030] This application's driving simulator converts the driver's driving intentions into signals recognizable by the VTCU vehicle controller. The VTCU vehicle controller then converts the driver's intentions using its internal control logic and controls the integrated vehicle powertrain model, EBS model, and various thermal management accessory models within the VTB real-time system through various hardware interfaces. Each system model calculates key signals such as energy consumption, temperature, and half-shaft transmission torque of each component in real time. The half-shaft transmission torque is transmitted to the TruckSim host computer through hardware interfaces. TruckSim calculates the vehicle speed in real time based on its internal residual vehicle model and environmental model. The driver observes the rendering effect on the TruckSim host computer and controls the vehicle's attitude through the driving simulator. Simulation calibration engineers continuously optimize various economic indicators of the vehicle by calibrating various control parameters of the VTCU in real time through the calibration host computer, forming a closed loop of simulation optimization.

[0031] Figure 1 This is a schematic diagram of a vehicle simulation system based on a VTB virtual test bench according to Embodiment 1 of the present invention; the system includes: a driver simulator 1, a VTCU vehicle controller 2, a TruckSim vehicle host computer 13, and a VTB virtual test bench 3;

[0032] The driver simulator 1 is used to convert the driver's intentions into steering wheel signals, throttle signals and braking signals of the whole vehicle; and send the steering signals and steering signals to the TruckSim vehicle host computer 13, and transmit the throttle signals and braking signals to the VTCU vehicle controller 2 through CAN communication;

[0033] The driver will press the pedals and turn the steering wheel more deeply according to the acceleration, deceleration and steering intentions. The driving simulator converts the pedal depth and steering angle signals into electrical signals that the model can recognize.

[0034] The VTCU vehicle controller 2 is the central control unit of the new energy vehicle and the core of the entire control system. The VTCU collects the status of the motor, battery, and transmission from the vehicle powertrain model 2, and is responsible for normal vehicle operation, energy management of the vehicle drive system and power battery, network management, fault diagnosis and handling, and vehicle status monitoring. In this application, the VTCU vehicle controller 2 generates a motor torque signal based on the throttle and braking signals; and collects the braking torque signal from the electronic braking unit in the VTB virtual test bench 3, achieving interlocking between the motor torque signal and the braking torque signal.

[0035] The process by which the VTCU vehicle controller 2 generates motor torque signals based on throttle and braking signals includes: the VTCU vehicle controller 2 uses the throttle pedal opening to perform a MAP lookup to obtain the corresponding torque value.

[0036] The process of interlocking the motor torque signal and the braking torque signal includes: when the electronic braking unit collects the braking torque signal, it issues a negative torque braking signal; the negative torque has the highest priority, and even if the accelerator is pressed deeply, the motor drive torque request is still 0, thus achieving the interlocking of the motor torque signal and the braking torque signal.

[0037] Figure 2 This is a schematic diagram of the connection of a vehicle simulation system based on a VTB virtual test bench, as proposed in Embodiment 1 of the present invention.

[0038] The driver simulator 1 is communicatively connected to the VTCU vehicle controller 2 and the TruckSim vehicle host computer 13, respectively; the VTB virtual test bench 3 is communicatively connected to the bus analysis unit KAVASER9 and the VTCU vehicle controller 2, respectively; the TruckSim vehicle host computer 13 is also communicatively connected to the bus analysis unit KAVASER9.

[0039] The VTCU vehicle controller 2 acquires signals from the vehicle thermal management model 8 in the VTB virtual test bench 3 to generate start / stop signals for various accessories. This mainly includes control MAP data for the cooling fan, water pump, battery air conditioning, etc. Temperature sensors read the temperature of each component and cooling system in real time, perform real-time lookup, and determine and execute the start / stop command for each component.

[0040] In this application, the VTB virtual test bench 3 consists of two hardware parts: a hardware communication port 4 and a VTB real-time system 6. The hardware communication port 4 enables the transmission of signals between the model and the real hardware, and can realize the mutual conversion of digital and analog signals, CAN communication, serial communication, and Ethernet communication. The VTCU vehicle controller 2 is connected to the VTB virtual test bench 3 through the hardware communication port 4 to realize the hardware-in-the-loop target of the VTCU vehicle controller 2 and the driver-in-the-loop target of the driving simulator 3. Similarly, the hardware and software communication port 4 of the VTB virtual test bench 3 is responsible for connecting with the bus analysis unit KAVASER9. The TruckSim host computer 13 communicates with the VTB virtual test bench 3 through CAN to ensure the complete closed loop of the simulation model.

[0041] The VTB real-time system 5 internally embeds a high-precision vehicle powertrain model 7, an EBS model, control logic 6, and an Amesim vehicle thermal management model 8, all based on the Simulink platform. The vehicle powertrain model 7 consists of a power battery model, a BMS model, a motor controller model, a motor model, a transmission model, and a driveshaft model. The Amesim vehicle thermal management model 8 consists of a cabin air conditioning system, a battery air conditioning system, a motor cooling unit, and an electronic control cooling unit.

[0042] The electronic braking unit 6 integrates control logic and is encapsulated in a black box. In the VTB virtual test bench 3, the electronic braking unit 6 calculates the motor feedback torque signal under braking conditions in real time based on the braking signal and vehicle speed signal; and sends the motor feedback torque signal to the vehicle powertrain model 7; the vehicle powertrain model 7 calculates the torque of the rear half-shaft of the transmission in real time based on the motor torque signal and the motor feedback torque signal.

[0043] The process by which the vehicle powertrain model 7 calculates the torque of the rear half-shaft of the transmission in real time based on the motor torque signal and the motor feedback torque signal includes: the vehicle controller multiplies the motor drive torque value or motor braking torque value by the speed ratio and efficiency value of the transmission in the current gear, and then divides by 2 to obtain the torque value of the rear half-shaft of the transmission.

[0044] TruckSim host computer 13 integrates the vehicle residual model, real scene model, and effect rendering project, excluding the power system. TruckSim host computer 13 is connected through the bus analysis unit KAVASER9 to receive the torque of the rear half shaft of the gearbox in real time. Based on the real scene model and vehicle residual model pre-set in TruckSim host computer 13, it calculates the vehicle attitude and speed in real time.

[0045] Real-world scene model construction: Based on point cloud data scanned by LiDAR and elevation and mileage data collected by VBOX, the scenery along the real road and key parameter information such as road elevation, roughness, and curvature are reproduced.

[0046] Vehicle residual model: including tires, body, and EBS model. Simplified feature models can be built based on the physical properties and mathematical characteristics of each component.

[0047] Vehicle speed and body posture calculation: Wheel torque is calculated based on the motor torque and powertrain transmission. Wheel resistance is estimated using the ABC coefficient. The difference between wheel torque and wheel resistance is used to calculate the vehicle's acceleration / deceleration status, speed, and other information.

[0048] In the VTB virtual test bench, the electronic braking unit calculates the mechanical braking torque signal under braking conditions in real time based on the braking signal and vehicle speed signal, and sends the mechanical braking torque signal to the host computer.

[0049] The vehicle powertrain model receives vehicle speed, body posture, motor feedback torque signals, mechanical braking torque signals, and the power of various accessories through a bus analysis unit, and calculates motor energy consumption, battery energy consumption, and overall vehicle energy consumption in real time. It acquires start-stop signals for various components via CAN bus data transmission and I / O interface transmission. The vehicle management model integrates thermal management MAP data and mathematical formulas for various components, enabling the calculation of system temperature and power consumption.

[0050] The simulation system also includes the ability to change the vehicle speed and attitude in real time by manipulating the driver simulator to achieve the target speed based on the vehicle posture and speed displayed on the host computer, thus realizing a closed loop of vehicle control.

[0051] The driver visually observes the key parameters of the vehicle displayed on the TruckSim host computer 13 and the vehicle posture on the TruckSim rendering effect display 10. By manipulating the driver simulator 1, the driver changes the vehicle speed and posture in real time to achieve the target speed, thus realizing a closed loop of vehicle control.

[0052] The system also includes a calibration unit, which communicates with the vehicle controller. This unit adjusts the vehicle or component parameters within the vehicle controller when the overall vehicle performance or the performance of individual components fails to meet expectations, thereby optimizing the overall vehicle performance or the performance of individual components. This application includes CANape calibration hardware 15 and CANape calibration software host computer 16. When the expected performance of the overall vehicle or individual components is not achieved, the CANape calibration hardware and software 15 is connected to the calibration CAN bus of the VTCU vehicle controller 2. Vehicle performance development engineers can quickly load A2L files through the CANape calibration software and access and modify VTCU memory parameters in real time through the ASMA-defined standard protocol XCP / CCP to achieve optimal performance of the overall vehicle and individual components, realizing a data closed loop for vehicle performance simulation and parameter optimization calibration.

[0053] The present invention, in embodiment 1, proposes a vehicle simulation system based on a VTB virtual test bench. This system takes into account the vehicle's power system and thermal management system, and adjusts the vehicle's driving status in real time according to environmental road factors and driver intentions. It calculates and evaluates the performance of various vehicle components, vehicle energy consumption, and the impact of human and environmental factors on the vehicle's economy in real time. It also performs online calibration and optimization based on the performance characteristics of each component, forming a closed loop of simulation and calibration data.

[0054] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that the elements inherent in a process, method, article, or apparatus that includes a list of elements are included. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element. Additionally, portions of the technical solutions provided in the embodiments of this application that are consistent with the implementation principles of corresponding technical solutions in the prior art have not been described in detail to avoid excessive elaboration.

[0055] While specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art can make other modifications or variations based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A vehicle simulation system based on a VTB virtual test bench, characterized in that, This includes a driver simulator, vehicle controller, host computer, and VTB virtual test bench; The driver simulator is used to convert the driver's intentions into steering wheel signals, accelerator signals and braking signals for the whole vehicle; and to send the steering signals and braking signals to the host computer, and to transmit the accelerator signals and braking signals to the vehicle controller; The vehicle controller generates a motor torque signal based on the throttle signal and the braking signal; and collects the braking torque signal of the electronic braking unit in the VTB virtual test bench to achieve interlocking of the motor torque signal and the braking torque signal. The process of interlocking the motor torque signal and the braking torque signal includes: when the electronic braking unit collects the braking torque signal, it issues a negative torque braking signal; the negative torque has the highest priority, and even if the accelerator is pressed deeply, the motor drive torque request is still 0, thus achieving the interlocking of the motor torque signal and the braking torque signal. The electronic braking unit in the VTB virtual test bench calculates the motor feedback torque signal under braking conditions in real time based on the braking signal and vehicle speed signal; and sends the motor feedback torque signal to the vehicle powertrain model; the vehicle powertrain model calculates the torque of the rear half-shaft of the transmission in real time based on the motor torque signal and the motor feedback torque signal. The process by which the vehicle powertrain model calculates the torque of the rear half-shaft of the transmission in real time based on the motor torque signal and the motor feedback torque signal includes: the vehicle controller multiplies the motor drive torque value or motor braking torque value by the speed ratio and efficiency value of the transmission in the current gear, and then divides by 2 to obtain the torque value of the rear half-shaft of the transmission. The host computer receives the torque of the rear half-shaft of the gearbox in real time, and calculates the vehicle attitude and speed in real time based on the real scene model and the vehicle residual model pre-set in the host computer; the vehicle residual model includes the tire, body and EBS models; The real-time reception of the transmission rear half-shaft torque by the host computer is specifically as follows: The host computer receives the transmission rear half-shaft torque through the bus analysis unit; the process of calculating the vehicle attitude and speed in real time based on the pre-set real scene model and vehicle residual model in the host computer includes: calculating the wheel-side torque based on the motor torque value and the transmission of the power chain; calculating the wheel-side resistance based on the ABC coefficient; and calculating the acceleration / deceleration state and speed information of the vehicle based on the difference between the wheel-side torque and the wheel-side resistance.

2. The vehicle simulation system based on a VTB virtual test bench according to claim 1, characterized in that, The simulation system also includes the ability to change the vehicle speed and attitude in real time by manipulating the driver simulator to achieve the target vehicle speed based on the vehicle posture and speed displayed on the host computer, thus realizing a closed loop of vehicle control.

3. The vehicle simulation system based on a VTB virtual test bench according to claim 1, characterized in that, The driver simulator is communicatively connected to the vehicle controller and the host computer, respectively; the VTB virtual test bench is communicatively connected to the bus analysis unit and the vehicle controller, respectively; the host computer is also communicatively connected to the bus analysis unit.

4. The vehicle simulation system based on a VTB virtual test bench according to claim 1, characterized in that, The process by which the vehicle controller generates a motor torque signal based on the throttle signal and the braking signal includes: the vehicle controller uses the throttle pedal opening to perform a MAP lookup table to obtain the corresponding torque value.

5. A vehicle simulation system based on a VTB virtual test bench according to claim 1, characterized in that, The vehicle controller acquires signals from the vehicle thermal management model in the VTB virtual test bench to generate start / stop signals for each accessory; The vehicle thermal management model in the VTB virtual test bench calculates the temperature of each power system and the power of each accessory based on the power information of each component in the power system model, the vehicle speed, and the start / stop signals.

6. A vehicle simulation system based on a VTB virtual test bench according to claim 5, characterized in that, The electronic braking unit in the VTB virtual test bench calculates the mechanical braking torque signal under braking conditions in real time based on the braking signal and vehicle speed signal, and sends the mechanical braking torque signal to the host computer. The vehicle powertrain model receives vehicle speed, body posture, motor feedback torque signal, mechanical braking torque signal and power of each accessory through the bus analysis unit, and calculates motor energy consumption, battery energy consumption and vehicle energy consumption in real time.

7. A vehicle simulation system based on a VTB virtual test bench according to claim 6, characterized in that, The system also includes a calibration unit, which is communicatively connected to the vehicle controller. The calibration unit is used to adjust the vehicle or component parameters in the vehicle controller when the overall vehicle performance or the performance of each component does not meet expectations, so that the overall vehicle performance or the performance of each component can reach the optimal level.

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