A new energy vehicle thermal management control development and verification platform and implementation method

Abstract

The present invention discloses a new energy vehicle thermal management control development and verification platform, including: a thermal management control development host computer and an experimental data processing system, an environmental laboratory control system, a thermal management HIL test system, a data acquisition system and a tested object; wherein the thermal management control development host computer and the experimental data processing system are respectively connected to the thermal management HIL test system and the data acquisition system; the thermal management HIL test system is respectively connected to the environmental laboratory control system and the tested object, and the tested object is an ECU system or an RCP system; the tested object is connected to the data acquisition system; the data acquisition system is connected to the environmental laboratory control system. The present invention provides a new energy vehicle thermal management control development and verification platform and an implementation method, which is scientifically designed and can quickly and reliably realize the development and verification of the control, performance and functions of the thermal management system.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile thermal management testing, and in particular to a new energy automobile thermal management control development and verification platform and an implementation method. Background Art

[0002] As people's requirements for automotive thermal management system (TMS) control are increasing, the structure of automotive thermal management systems is becoming more and more diverse. The automotive thermal management system is of great significance to the energy saving, comfort and safety of the entire vehicle.

[0003] Unlike fuel vehicles, the thermal management system of new energy vehicles includes not only air conditioning (AC), but also the circuits of batteries and motors, as well as thermal management of generators, chargers, and various controllers. Batteries are the core components of new energy vehicles. Taking the thermal management of battery packs as an example, it includes multiple functions such as preheating, charging, cooling, and heat preservation. Good thermal management of battery packs and control of safe operation of power batteries are of great significance to the safety and performance of the entire vehicle.

[0004] Similarly, smart cockpits have also received more and more attention in recent years. The comfort of the cockpit is closely related to the smart strategy of air conditioning. A good automotive thermal management system integrates air conditioning, battery packs, motors and various controllers to achieve overall performance, comfort improvement and energy consumption reduction in the car.

[0005] At present, the development cycle of automotive thermal management is short, the thermal management structure of new energy vehicles is becoming more and more complex, and the control strategy of thermal management system has become the focus of research. The working conditions of automotive thermal management system have the characteristics of instantaneous and dynamic changes, and are affected by many factors such as external environment, vehicle performance, driving status, passenger flow, etc. A good automotive thermal control strategy needs to respond in time according to the changes in working conditions and ensure control accuracy.

[0006] In addition, the thermal management system of new energy vehicles includes multiple systems such as the passenger compartment, battery, and motor, and multiple systems affect each other, which puts higher requirements on the thermal management system. However, the market's requirements and efficiency for vehicle development are gradually increasing, making the development of thermal systems must be fast. However, the industry currently lacks a mature one-stop integrated platform for thermal system development and testing.

[0007] In addition, the reliability of the thermal system is a very important part of the vehicle performance development. It has the characteristics of multiple inputs and outputs. In the development, it is necessary to meet both the performance requirements of the thermal system and the control requirements of the thermal system, so more costs will inevitably be invested in the testing link. However, the cost of repeated testing on different test benches is very high, which will waste a lot of resources and time in the entire development cycle, which is also inconsistent with the current shortening cycle of vehicle development.

[0008] Therefore, it is very necessary to develop an integrated thermal management platform that integrates software and hardware development and testing.

[0009] It should be noted that hardware-in-the-loop (HIL) testing is a very important part of the system verification test in the V-shaped development process. Through HIL testing, it is possible to test virtual extreme environments and fault conditions in advance, greatly shortening the test and verification cycle. However, at present, HIL testing in the automotive industry is mainly used in the testing business of control units such as vehicle VCU, power battery BMS, chassis, steering, ABS, and intelligent driving. There are very few applications in the field of thermal systems, and hardware-in-the-loop testing of controllers in the control system of the thermal system field is urgently needed. At the same time, HIL testing requires corresponding real-time models to simulate the thermal system to complete the test verification. The accuracy of the test results has high requirements for the simplified model. If there is no suitable and accurate model, the test and verification of the thermal system cannot be achieved. The real-time model of the thermal system involved in the HIL system is not currently available in the industry and is still a vacant part of this solution. Summary of the invention

[0010] The purpose of the present invention is to provide a new energy vehicle thermal management control development and verification platform and implementation method in view of the technical defects in the prior art.

[0011] To this end, the present invention provides a new energy vehicle thermal management control development and verification platform, including: a thermal management control development host computer and an experimental data processing system, an environmental laboratory control system, a thermal management HIL test system, a data acquisition system and a tested object;

[0012] The object under test is an ECU system or an RCP system;

[0013] Among them, the thermal management control development host computer and experimental data processing system are connected to the thermal management HIL test system and data acquisition system respectively;

[0014] Thermal management HIL test system, connected to the environmental laboratory control system and the object under test;

[0015] The object under test is connected to the data acquisition system;

[0016] Data acquisition system, connected to the environmental laboratory control system.

[0017] In addition, the present invention also provides an implementation method of the new energy vehicle thermal management control development and verification platform as described above, comprising the following steps:

[0018] Step S1, determining different test operations to be performed according to specific test requirements, whether there is a thermal system actuator 8, and whether the environmental laboratory 4 is required to provide a real experimental environment;

[0019] Step S2, obtaining corresponding test data by executing the first test operation and the second test operation respectively;

[0020] The first test operation is performed only when the platform includes a thermal system actuator 8 as a physical object and the environmental laboratory 4 is required to provide a real experimental environment, while the second test operation does not require the platform to include a thermal system actuator 8 as a physical object;

[0021] Step S3, test data upload and analysis and processing: the test data obtained in step S2 is uploaded to the thermal management control development host computer and the data processing system 1 for analysis and processing.

[0022] It can be seen from the technical solution provided by the present invention that, compared with the prior art, the present invention provides a new energy vehicle thermal management control development and verification platform and implementation method, which is scientifically designed and can quickly and reliably realize the control, performance and function development and verification of the vehicle-mounted thermal management controller (such as an ECU system or an RCP system), and has great practical significance.

[0023] After inspection, it is found that the present invention can complete semi-physical and semi-virtual simulation tests of thermal system benches and complete vehicles after application.

[0024] For the present invention, in this test platform, there are real elements such as temperature, humidity, sunlight and air volume provided by real control unit ECU or RCP system, real thermal system physical devices and real environmental laboratory, and there is a real-time simulation model of the controlled object in the host computer. The physical and virtual models are connected together through the experimental platform to form a closed loop, and jointly complete the verification and testing of various characteristics of the controlled object. This test result is very close to the actual result, which is a simulation test technology.

[0025] In the present invention, the thermal system bench is a test bench for performing various tests on the thermal system. Bench test refers to the fact that before a product leaves the factory, it is generally necessary to conduct certain simulated trial run tests, and only after passing the tests can it be put into use. The thermal system bench referred to in the present invention is a tool for judging and testing the cooling and heating performance and control accuracy performance of the thermal system before the thermal system is officially put into production.

[0026] In the present invention, the simulation test performed refers to hardware-in-the-loop testing, which is a test method applied in the field of automotive electronic control systems. It connects actual hardware (such as ECU or RCP system, sensor, actuator, etc.) with simulation devices (such as models, experimental data management system of the host computer, etc.) through interfaces, simulates the actual operating environment, and tests and evaluates the real-time running system to ensure the performance, stability and reliability of the automotive thermal management control system.

[0027] By applying the present invention, the gap in HIL testing in the current automotive thermal management field is filled, and a complete one-stop thermal management development and testing solution combining a real-time software model, a hardware platform construction, and an environmental laboratory can be provided.

[0028] It should be noted that the present invention discloses a development and verification test platform in the field of automotive thermal management system control. Based on this platform, the vehicle thermal management performance, control strategy verification development and verification work can be realized, and a one-stop service for automotive thermal management development test verification can be completed. The present invention is based on the controller hardware-in-the-loop (HIL) testing technology, combined with thermal system benches, environmental laboratories, rapid control prototyping (RCP) systems, etc., to realize semi-physical simulation testing of thermal systems in the field of automotive thermal management control, and complete the function and performance verification, control strategy verification, extreme environment verification and thermal system testing in virtual vehicles in the thermal system development. Ultimately, the development of thermal management and vehicle-level control strategy development can be realized, which significantly shortens the development time and effectively improves the development efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 The overall structural block diagram of a new energy vehicle thermal management control development and verification platform provided by the present invention;

[0030] Figure 2 A block diagram of the connection structure between a thermal management HIL (hardware in the loop) test system and a thermal management system to be tested in a new energy vehicle thermal management control development and verification platform provided by the present invention;

[0031] Figure 3 A basic flow chart of an implementation method of a new energy vehicle thermal management control development and verification platform provided by the present invention;

[0032] Figure 4 The present invention provides an overall flow chart of an implementation method of a new energy vehicle thermal management control development and verification platform. DETAILED DESCRIPTION

[0033] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0034] In the description of this patent, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", and "set" should be understood in a broad sense, for example, it can be fixedly connected or set, or it can be detachably connected or set, or connected or set in one piece. For ordinary technicians in this field, the specific meanings of the above terms in this patent can be understood according to specific circumstances.

[0035] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.

[0036] See also Figures 1 to 4 , the present invention provides a new energy vehicle thermal management control development and verification platform, including: a thermal management (TMS) control development host computer and experimental data processing system 1, an environmental laboratory control system 2, a thermal management HIL test system 3, a data acquisition system 5 and a test object 7;

[0037] The test object 7 is an ECU system or an RCP system, which is an on-vehicle thermal management controller;

[0038] Among them, the thermal management control development host computer and the experimental data processing system 1 are connected to the thermal management HIL test system 3 and the data acquisition system 5 respectively;

[0039] The thermal management HIL test system 3 is connected to the environmental laboratory control system 2 and the test object 7 respectively;

[0040] The tested object 7 is connected to the data acquisition system 5;

[0041] The data acquisition system 5 is connected to the environmental laboratory control system 2 .

[0042] It should be noted that the object under test is the ECU or RCP system. The ECU electronic control unit is used to calculate, process and judge the information input by various sensors according to the programs and data stored in it, and then output instructions to the actuator to control the actuator to complete the corresponding action. The ECU electronic control unit is composed of a microcomputer, input, output and control circuits, etc. The code and control strategy in the ECU or RCP system need to be tested and verified to ensure safe boarding and the performance of the control system.

[0043] In the present invention, based on the new energy vehicle thermal management control development and verification platform, the present invention can provide a thermal management development and verification method. The platform proposes a virtual-real combined, real-time switching thermal management control development and verification method based on HIL testing technology.

[0044] The new energy vehicle thermal management control development and verification platform provided by the present invention includes two working modes: working mode 1 and working mode 2. These two working modes can be implemented and switched on the same platform provided by the present invention. The specific description is as follows:

[0045] In the present invention, for the new energy vehicle thermal management control development and verification platform provided by the present invention, when the platform includes a thermal system actuator 8 as a physical object and requires an environmental laboratory 4 to provide a real experimental environment, the platform can execute the following working mode 1:

[0046] The thermal management HIL test system 3 is connected to the environmental laboratory control system 2 and is used to send a control signal to the environmental laboratory control system 2;

[0047] The environmental laboratory control system 2 is used to receive control signals from the thermal management HIL test system 3 to control the environmental laboratory 4. After the environmental boundary conditions such as temperature, humidity, sunlight radiation intensity, etc. in the environmental laboratory 4 are generated, the thermal system sensor 6 receives the temperature, humidity and other signals and converts them into electrical signals and transmits them to the ECU or RCP system. The thermal system actuator 8 performs corresponding actions according to the control signal issued by the ECU or RCP system (the object under test 7).

[0048] The thermal system sensor 6 and the thermal system actuator 8 must be located inside the environmental laboratory 4;

[0049] In terms of specific implementation, the environmental laboratory 4 is used to provide a real experimental environment, including: temperature, humidity, wind speed, wind volume, water temperature and sunlight environment.

[0050] The thermal system sensor 6 provided in the environmental laboratory 4 is used to detect the environmental parameters (such as temperature, humidity, wind speed, air volume, water temperature and sunlight intensity) in the environmental laboratory 4, and then send them to the tested object 7 and the data acquisition system 5;

[0051] It should be noted that, in the present invention, the environmental laboratory 4 is an environmental chamber, which is used to provide corresponding environmental boundaries for the tested ECU or RCP system (test object 7), such as configurable parameters such as temperature, humidity, sunlight intensity, wind speed, etc., and can also provide feedback for the tested object to form a closed loop of control and testing, which can make the test results closer to the actual situation and improve the accuracy of the test.

[0052] The tested object 7 is used to receive the environmental data sent by the thermal system sensor 6, obtain the corresponding control signal according to the existing thermal management control strategy, and then send it to the corresponding thermal system actuator 8 to drive the thermal system actuator 8 to operate;

[0053] The data acquisition system 5 is connected to the thermal system sensor 6, the test object 7 and the thermal system actuator 8 respectively, and is used to collect the environmental parameters in the environmental laboratory 4 in real time, and send them to the thermal management (TMS) control development host computer and the experimental data processing system 1. The thermal management (TMS) control development host computer and the experimental data processing system 1 determine whether the environmental parameters in the environmental laboratory 4 meet the control requirements (that is, whether the control requirements of the existing thermal management control strategy on the test object 7 are met, that is, whether the thermal system actuator 8 performs the corresponding action according to the control signal of the thermal system actuator 8).

[0054] It should be noted that, in the present invention, the thermal system actuator 8 refers to various types of thermal system actuators, such as electric compressors, blowers, water pumps, PTCs, electronic expansion valves, thermal expansion valves, damper motors, etc. Temperature, humidity, wind speed, air volume, and sunlight environment are environmental parameters from the environmental laboratory 4.

[0055] It should be noted that, in the present invention, the function of the multiple thermal system actuators 8 is to verify whether the control strategy in the ECU or RCP system is correct, and to verify whether the control system of the thermal system can reliably execute the corresponding control signals according to the control strategy.

[0056] It should be noted that in working mode 1, the corresponding control signal is transmitted to the thermal system actuator 8 through the IO interface of the controller, driving the thermal system actuator 8 to operate, and collecting relevant data to determine whether it is executed according to the control strategy. Taking the working condition of battery heating in a car as an example, after the thermal system sensor 6 measures that the temperature of the battery water circuit is low, it converts the measured water temperature into an electrical signal and transmits it to the ECU or RCP system. The ECU or RCP calculates according to the control strategy that the current battery pack has a need to heat up, so it outputs a control signal to turn on the PTC heating function. Then, after receiving the control signal, the PTC in the thermal system actuator 8 starts to work at a certain power. At this time, the data acquisition system 8 collects the water temperature signal in the battery pack water circuit in real time and uploads it to the thermal management control development host computer and the data management system 1, so as to observe and analyze whether the battery temperature reaches the preset temperature.

[0057] It should be noted that, in specific implementation, in the above-mentioned working mode 1, physical objects such as environmental laboratories or thermal system benches can be added to the overall testing process, and the thermal system benches act according to real-time signals sent by the ECU or RCP system.

[0058] In the present invention, for the new energy vehicle thermal management control development and verification platform provided by the present invention, regardless of whether the platform includes a thermal system actuator 8 as a physical object, the platform can execute the following working mode 2:

[0059] Thermal management HIL test system 3, used to send virtual signals to the ECU or RCP system (test object 7);

[0060] The object under test 7 (i.e., ECU or RCP system) is used to analyze the virtual signal according to the existing thermal management control strategy and thermal system real-time model, obtain the corresponding control signal, and then return it to the thermal management HIL test system 3;

[0061] The thermal management HIL test system 3 is used to judge the control signal returned by the test object 7 (i.e., ECU or RCP system) according to the real-time model of the thermal system it has, so as to complete the virtual test operation. Specifically, for the thermal management HIL test system 3, it is used to judge whether the control signal returned by the test object 7 (i.e., ECU or RCP system) meets the design requirements (i.e., whether it is correct, that is, when the control signal is input into the real-time model of the thermal system in the real-time machine of the thermal management HIL test system 3, whether it meets the design requirements of the real-time model of the thermal system), and the requirements can be divided into: performance requirements, safety requirements, and reliability requirements.

[0062] It should be noted that the virtual signal is a signal that is sent directly to the ECU or RCP system (test object 7) by the IO board of the thermal management HIL test system 3. For example, a virtual signal of PTC heating is given in the simulation model of the thermal system. After the virtual signal is received by the ECU or RCP system (test object 7), the ECU or RCP system outputs a corresponding execution signal (i.e., control signal) after calculation according to the internal control logic or algorithm to verify whether the control strategy in the ECU or RCP system is correct. The virtual signal, for example, can be a blower duty cycle, a compressor target speed, a water pump duty cycle, and other signals obtained by model calculation.

[0063] In the present invention, virtual signals are used to verify whether the control strategy in the ECU or RCP system is correct, and the reliability and accuracy of the automotive thermal management control system. For example, the control signal sent by the ECU will be returned to the real-time model of the thermal system running on the real-time machine in the thermal management HIL test system 3. The real-time model provides a simulation environment for the control signal, simulating the situation where the control signal is transmitted to the real vehicle or the test bench. Because the controlled object is virtual, HIL testing is safer and more efficient than real vehicle testing, and can test some extreme situations that are not easy to achieve in real vehicle testing. In addition, the HIL test system has rich test functions, and can realize the reusability of the test platform, etc., which greatly saves time and economic costs.

[0064] It should be noted that, in specific implementation, in the above-mentioned working mode 2, there is no physical thermal system (such as the environmental laboratory 4) involved, and the control signal of the thermal system only interacts between the thermal management HIL test system 3 and the ECU or RCP system (test object 7).

[0065] It should be noted that the thermal management control strategy and the thermal system real-time model are specifically the thermal system real-time model that has been downloaded and compiled into the real-time machine of the thermal management HIL test system 3, and the thermal management control strategy downloaded and compiled into the ECU or RCP system.

[0066] Among them, the thermal management control strategy is the control center of the entire vehicle, which needs to be determined based on user usage scenarios, user needs and the configuration of its own thermal system.

[0067] The real-time model of the thermal system is a thermal system model developed according to the needs. The real-time model of the thermal system provides a virtual model for testing the thermal management function of the ECU or RCP system, and verifies the accuracy of the thermal management function test in the ECU or RCP system.

[0068] In the present invention, in terms of specific implementation, in order to realize the thermal management function test, the thermal management real-time model provided by the platform of the present invention includes: an automobile air-conditioning model, a battery model, a motor model, a whole vehicle model, an environmental model and a driving model; among them, the automobile air-conditioning model is used to verify the air-conditioning cooling and heating capabilities, the battery model is used to verify the battery thermal insulation cooling performance and strategy, the motor model is used to verify the cooling performance of the motor, and the whole vehicle model is used to verify various virtual working conditions.

[0069] In the present invention, the control signal corresponding to the virtual signal is the control signal that the thermal management controller or the RCP rapid prototype controller (ie the object under test 7) ​​obtains through the control strategy after receiving the virtual signal.

[0070] In the present invention, in working mode 2, the control signal corresponding to the virtual signal needs to be transmitted back to the real-time machine through the IO board in the thermal management HIL test system 3, and the real-time simulation model (i.e., the thermal system real-time model) in the real-time machine of the thermal management HIL test system 3 receives the signal and verifies it in a real-time simulation manner; for example, there is an existing battery real-time model running in the real-time machine. When the battery needs to be heated, the thermal management HIL test system 3 will send a virtual signal that needs to be heated to the ECU or RCP system, and obtain the control signal of the PTC heating power after calculation according to the control strategy. The PTC heating signal is transmitted back to the battery real-time model in the real-time machine of the thermal management HIL test system 3, and the PTC model in the simulation (i.e., the battery real-time model) starts to heat. At this time, it is observed whether the temperature of the battery pack has reached the preset heating temperature. If reached, it means that the performance of the battery heating condition tested at this time meets the design requirements and the test under this condition passes; if the battery pack does not reach the preset temperature, it means that the ECU or RCP system (i.e., the test object 7) does not meet the performance design requirements. If the design requirements are not met, the control strategy in the ECU or RCP system needs to be optimized and modified according to the test results.

[0071] It should be noted that, for the present invention, in working mode two, the thermal management HIL test system sends a virtual signal to the ECU or RCP system (i.e., the object under test 7), and the ECU or RCP responds according to the existing thermal management control strategy and the calculation and analysis of the thermal system model, and transmits the control signal to the thermal management HIL test system. The thermal management HIL test system then identifies the control signal of the ECU or RCP system (i.e., the object under test 7) ​​to complete the test content.

[0072] For the present invention, in working mode 2, see Figure 2 As shown, the thermal management HIL test system 3 includes: a programmable power supply, a real-time controller, an IO board, a signal conditioning module, a fault circuit, a normal circuit and a terminal box;

[0073] The real-time controller is a CPU used to run a real-time operating system and is the core of the hardware-in-the-loop device. The host computer in the thermal management (TMS) control development host computer and experimental data processing system 1 downloads the real-time model of the thermal system to the real-time controller of the thermal management HIL test system 3 for operation;

[0074] A real-time controller is used to run the real-time model of the thermal system.

[0075] Programmable power supply, used to simulate the on-board power supply and supply power to various IO or communication boards;

[0076] IO board, as a communication board, is used to interact with ECU signals;

[0077] The signal conditioning module is used to perform signal conditioning when the signal specifications of the IO board are different from those of the ECU.

[0078] It should be noted that the real-time model of the thermal system (i.e., the test virtual model with thermal management function) provides a test virtual model of the thermal management function of the ECU or RCP system, which can verify the accuracy of the thermal management function test in the ECU or RCP system.

[0079] In specific implementation, the thermal management HIL test system 3 is also connected to one end of the fault circuit and the normal circuit respectively through the connection terminal box;

[0080] The other ends of the fault circuit and the normal circuit are connected to the object under test 7 through the connection terminal box.

[0081] It should be noted that, in order to test the reliability of the thermal system control function, the behavior of the ECU or RCP system under specific fault conditions as the test object 7 is tested or verified. The thermal management control development and verification platform in the present invention also provides: fault loops and normal loops for selection, which can realize the normal function test of the thermal management control system and the control function test after the fault occurs.

[0082] It should be noted that the fault loop refers to the fault injection module. In the HIL test system, the corresponding fault can be set for each IO input and output according to the situation of the object under test. The faults include short circuit, open circuit, short circuit to ground, special signal and other problems. The conventional loop refers to the module that is tested normally without fault injection. These two loops can realize function switching.

[0083] The significance of fault injection is to simulate the faults that the thermal system may encounter in actual situations, so as to observe how the ECU or RCP system handles the faults, whether it can handle the faults safely, and ensure that the software functions in the ECU or RCP system are reliable.

[0084] Among them, the conventional loop only tests the functions of the software in the ECU or RCP system to test whether it can achieve the designed performance level. The fault loop is used as a comparison to verify whether the ECU or RCP system can make correct and safe outputs in response to the fault.

[0085] Among them, the fault loop is used to simulate different types of fault conditions to realize the testing of failure modes; the fault conditions include sensor failure, communication fault injection, power supply fault injection and thermal system failure.

[0086] It should be noted that in general HIL testing, the fault loop generally refers to fault injection, which generally includes the following situations: sensor fault, communication fault injection, power supply fault injection, and specific electrical faults such as sensor short circuit to ground, communication signal open circuit, power supply short circuit to ground, etc. In actual hardware, the fault loop is implemented by a FUI fault injection board. The fault injection part is inserted between the IO board interface and the ECU or RCP system.

[0087] In addition, the thermal management HIL test system is aimed at the thermal management control system of new energy vehicles. In this experimental method, special faults of the thermal system are also designed, and corresponding faults are designed for the thermal system. The fault simulation of the thermal system creates fault signals by the fault circuit. In the thermal system, valve blockage can create a signal of high pressure and high temperature of the compressor exhaust through the fault circuit, and the sudden increase of flow resistance in the flow channel and the failure of the water pump can be realized by creating the temperature increase of the battery motor and the abnormal temperature of the battery inlet and outlet water. The fault circuit designs various thermal management faults according to the thermal system currently being tested. Finally, the fault test is carried out based on the working environment of the thermal system, such as the test of the working environment boundary and the test of the thermal system environmental conditions exceeding the design conditions.

[0088] In summary, for the two working modes provided by the present invention, it should be noted that working mode 1 requires a physical thermal system actuator and an environmental laboratory to complete the test, while working mode 2 can complete the test regardless of whether there is a thermal system actuator 8.

[0089] In terms of specific implementation, for the present invention, combined with the above two test working modes of the platform, different test modes can be provided for different test conditions. During the test, any different test mode can be selected to complete the test of the thermal management control system function, and realize the virtual verification of the thermal system control and the physical verification of the thermal system bench.

[0090] In the present invention, the specific implementation is as follows: Figure 1 As shown, the thermal management (TMS) control development host computer and the experimental data processing system 1 are respectively connected to the thermal management HIL test system 3 and the data acquisition system 5 through Ethernet.

[0091] In the present invention, the specific implementation is as follows: Figure 1 As shown, the tested object 7 realizes data communication with the data acquisition system 5 through CAN.

[0092] In order to better understand the present invention, the functions of each component of the platform of the present invention are described in detail below.

[0093] See also Figure 1 As shown, in the present invention, the thermal management (TMS) control development host computer and experimental data processing system 1 includes the following functions:

[0094] 1. Monitor and control the operating status of the real-time machine in the thermal management HIL test system 3, including obtaining the operating status of the real-time machine, sending control commands, etc.;

[0095] 2. Collect test data;

[0096] 3. Data processing and analysis, thermal management (TMS) control development host computer and experimental data processing system 1 The host computer processes and analyzes the collected data to determine the status and problems of the current model and system;

[0097] 4. Store data for later analysis and processing.

[0098] 5. The thermal management (TMS) control development host computer and experimental data processing system 1 communicates with the real-time machine in the thermal management HIL test system 3 through Ethernet to send control signals to control the thermal management HIL test system 3, and communicates with the data acquisition system 5 through Ethernet to send the data collected by the acquisition sensor.

[0099] In the present invention, the environmental laboratory control system 2 includes the following functions:

[0100] 1. In view of the fact that the experimental platform of the present invention can provide a real test environment for testing, the real environment is provided by the environmental laboratory 4, and the environmental laboratory control system 2 is used to send control signals to the controlled devices (such as fans, solar simulators and other actuators) in the environmental laboratory 4 to achieve control of the actuators in the environmental laboratory 4. Among them, the control signals include but are not limited to: switch control signals of fans and solar simulators, control signals for the power output of solar simulators, control signals for the wind speed output of fans, etc.

[0101] 2. In working mode 1, the environmental laboratory control system 2 is used to receive the control signal from the thermal management HIL test system 3, and then output the corresponding actuator control signal to the corresponding thermal system actuator 8; for example, when the thermal management HIL test system sends a control signal to control the wind speed to 60km / h, the environmental laboratory receives the signal and converts it, and then sends a control signal that can directly control the fan in the environmental laboratory 4, driving the fan to operate and output a wind speed of 60km / h.

[0102] In the present invention, the thermal management HIL test system 3 refers to the hardware part of the HIL test, which includes a real-time machine, a programmable power supply, and various IO boards configured to realize various functions. Working mode 1 must have the physical participation of the thermal system. In working mode 1, the real-time machine in the thermal management HIL test system 3 outputs the signal to the environmental laboratory control system 2 through the IO board to realize real-time control of the real environment. Working mode 2 can be without the physical participation of the thermal system. In working mode 2, after the thermal management (TMS) control development host computer and the host computer in the experimental data processing system 1 download the simulation model of the test (i.e., the real-time model of the thermal system) to the real-time machine of the thermal management HIL test system 3, the real-time machine outputs the signal to the ECU or RCP system (i.e., the object under test 7) ​​through various IO boards configured in advance.

[0103] In the present invention, the data acquisition system 5 is a real-time data acquisition system that can automatically collect and process data in real time. The core of the real-time data acquisition system is the data acquisition card or module. The real-time data acquisition system can convert the analog electrical signals output by the thermal system sensor 6 into digital signals, and transmit these signals to the host computer or experimental data management platform in the thermal management (TMS) control development host computer and the experimental data processing system 1 through the CAN bus or Ethernet communication interface. The data acquisition system 5 needs to collect data from the thermal system sensor 6, the ECU or RCP system (test object 7) and the thermal system actuator 8.

[0104] In the present invention, the ECU or RCP system (test object 7): it represents a controller with thermal management function or a thermal management controller built by rapid prototyping method. The ECU or RCP system under test is used to receive data from the thermal system sensor 6 as boundary conditions, send control signals according to the control algorithm or strategy in the controller, and the thermal system actuator 8 executes after receiving the control signal. The data acquisition system 5 collects the data of the execution status of the thermal system and uploads it to the thermal management (TMS) control development host computer and experimental data processing system 1.

[0105] In the present invention, in specific implementation, for the thermal management (TMS) control development host computer and experimental data processing system 1, the thermal management (TMS) control development host computer it has is any computer that can run the test software as hardware, generally equipped with i5 and above processors, 8GB running memory. For example, dSPACE's Control Desk or NI's Labview software is an experimental data processing system, and its specific function is to build a program or software with a GUI interface for experimental data management and processing based on test cases and specific model test conditions.

[0106] In the present invention, in specific implementation, for the environmental laboratory control system 2, the laboratory control system of ETS company can be selected to complete the control of the laboratory.

[0107] In the present invention, in terms of specific implementation, for the thermal management HIL test system 3, hardware from multiple companies such as dSPACE, Speedgoat or NI can be selected, and the specific model may be determined based on the input and output required by the actual test case and the required computing power.

[0108] In the present invention, in terms of specific implementation, for the data acquisition system 5, the data acquisition system of dewesfot can be selected to complete the real-time acquisition of the thermal system sensor 6, ECU or RCP system (test object 7) and thermal system actuator 8, and transmit these signals to the thermal management (TMS) control development host computer and the host computer or experimental data management platform of the experimental data processing system 1 through the CAN bus or Ethernet communication interface.

[0109] In the present invention, in specific implementation, the tested ECU or RCP system (test object 7), which represents a controller with thermal management function or a thermal management controller built using a rapid prototyping method, is the test object of the HIL test. Among them, ECU is an on-board electronic control unit with thermal management function, and the RCP rapid prototype controller can be implemented using the solutions of Speedgoat and dSPACE.

[0110] See also Figure 3 , Figure 4 As shown, based on Figure 1 , Figure 2 The present invention provides a new energy vehicle thermal management control development and verification platform, and the present invention also provides an implementation method of the new energy vehicle thermal management control development and verification platform, which specifically includes the following operations:

[0111] Step S1, determining different test operations to be performed according to specific test requirements, whether there is a thermal system actuator 8, and whether the environmental laboratory 4 is required to provide a real experimental environment;

[0112] It should be noted that the working mode 1 mentioned in the above text requires a physical thermal system actuator to complete the test, while the working mode 2 can be carried out without a physical thermal system actuator; the test method proposed in the present invention includes these two working modes, and whether there is a physical thermal system actuator involved is a method to distinguish the two working modes.

[0113] Step S2, obtaining corresponding test data by executing the first test operation and the second test operation respectively;

[0114] The first test operation is performed only when the platform includes the thermal system actuator 8 as a physical object and the environmental laboratory 4 is required to provide a real experimental environment, while the second test operation can be performed regardless of whether the platform includes the thermal system actuator 8 as a physical object (that is, the second test operation has no requirement for the physical object and can be performed with or without the physical object);

[0115] It should be noted that before the platform of the present invention is implemented, a thermal management control demand analysis needs to be performed. According to the current requirements of the thermal management control of the whole vehicle, a demand analysis is performed on the whole vehicle or the thermal system. Analyze the thermal system configuration and component components. According to the requirements of the thermal management control function, a list of thermal system requirements is made, and the thermal system configuration and component components are designed and arranged. Then, the test conditions are divided and test cases are designed. Different test strategies are designed according to the thermal system components or thermal system control strategies that need to be tested under different conditions.

[0116] In the present invention, in specific implementation, in step S2, the first test operation includes the following steps:

[0117] Step S211, building a physical model and configuring an embedded system: in the thermal management HIL test system 3, a physical model of the thermal system (i.e., a thermal management real-time model) is built according to a pre-designed thermal system configuration, and an ECU or RCP system corresponding to the physical thermal system is configured;

[0118] Step S212, building a thermal management development verification environment: configuring the ECU or RCP system as the test object, connecting the ECU or RCP system with the thermal system sensor 6 and the thermal system actuator 8, and ensuring signal transmission between the thermal system actuator 8 and the thermal system sensor 6 of the ECU or RCP system;

[0119] At the same time, connect the thermal management HIL test system 3, the thermal management control development host computer and data processing system 1, the environmental laboratory control system 2 and the data acquisition system 5, and then connect the ECU or RCP system, the thermal system sensor 6 and the thermal system actuator 8 to the entire development and verification platform to achieve normal communication between the various parts and complete the construction of the thermal management development and verification environment;

[0120] Step S213, thermal management test case implementation: the environmental laboratory control system 2 is directly controlled by the thermal management HIL test system 3. According to the requirements of the test case, the environmental laboratory 4 is used to provide a corresponding, simulated real experimental environment (including temperature, humidity, wind speed, air volume, sunlight and other environments). The thermal system sensor 6 installed in the environmental laboratory 4 detects the environmental parameters in the environmental laboratory 4 (such as temperature, humidity, wind speed, air volume and sunlight intensity), and then sends them to the ECU or RCP system as the tested object. The ECU or RCP system then controls the corresponding thermal system actuator 8 according to the pre-stored thermal management control strategy;

[0121] Step S214, test data collection: the data acquisition system 5 receives the signals output by the thermal system actuator 8 installed in the environmental laboratory 4 (such as working status signals) and the signals collected by the thermal system sensor 6 (such as environmental parameter signals) through the CAN communication method, thereby completing the collection of test data.

[0122] In the present invention, in specific implementation, in step S2, the second test operation includes the following steps:

[0123] Step S221, building a real-time model of the thermal system: according to the test requirements, for different thermal management function tests, corresponding real-time simulation models of the thermal system (i.e., real-time models of the thermal system) are built respectively;

[0124] It should be noted that, in a specific implementation, the real-time model of the thermal system is downloaded and compiled into a real-time controller of the thermal management HIL test system for execution.

[0125] Step S222, determining whether a fault test is required: if a fault test is required, adding a thermal management fault loop to the test link; if a fault test is not required, selecting a conventional loop for testing;

[0126] It should be noted that a thermal management fault loop can be set according to the characteristics of the thermal system to provide two test modes, namely a fault loop and a normal loop, for the thermal management function test and support real-time switching.

[0127] Step S223, test case implementation, obtaining test data: the thermal management HIL test system 3 sends a virtual signal (such as temperature, wind speed, vehicle speed, sunlight and other virtual signals) to the ECU or RCP system of the object under test. After receiving the virtual signal, the ECU or RCP system sends a corresponding control signal according to the existing control strategy. The thermal management HIL test system 3 then receives the control signal of the ECU or RCP system and determines whether the control signal meets the design requirements.

[0128] It should be noted that in the present invention, the real-time model of the thermal system (i.e., the real-time simulation model of the thermal system) is a model that provides a simulation environment for real-time testing. When there is no physical thermal system (i.e., the thermal system actuator 8), it is impossible to judge whether the control signal sent by the ECU or RCP system is correct based on the action of the thermal system actuator. Building a real-time simulation model provides a virtual verification environment to form a closed-loop test. The real-time simulation model of the thermal system is simulated according to the real characteristics of the devices in the thermal system, including sensors, compressors, water pumps and other devices. Therefore, it is reasonable and accurate to form a closed-loop test with a real-time simulation model. For example, there is a real-time battery model running in a real-time machine. When the battery needs to be heated, a virtual signal that needs to be heated will be sent to the ECU or RCP system, and the control signal of the PTC heating power will be obtained after calculation according to the control strategy. The PTC heating signal is transmitted back to the real-time model of the battery in the thermal management HIL test system, and the PTC model in the simulation starts to heat up. At this time, it is observed whether the temperature of the battery pack has reached the preset heating temperature. If it is reached, it means that the performance of the battery temperature rise condition tested at this time meets the design requirements, and the test under this condition passes; if the battery pack does not reach the preset temperature, it means that the ECU or RCP system does not meet the performance design requirements. If the design requirements are not met, the control strategy in the ECU or RCP system needs to be optimized and modified according to the test results.

[0129] Step S3, test data upload and analysis and processing: upload the test data obtained in step S2 to the thermal management control development host computer and data processing system 1 for analysis and processing;

[0130] In step S3, the thermal management control development host computer and the data processing system 1 can further process and analyze the test data as needed. Through the test data processing and analysis, it can be obtained whether the thermal management control function is achieved and whether the thermal management performance meets the design requirements.

[0131] Among them, the key point of whether the thermal management control function is realized is: whether the control of the thermal management control system can be completed according to the control strategy, that is, in the case of working mode one, whether the thermal system actuator performs the corresponding action according to the control signal, and in the case of working mode two, whether the ECU or RCP system outputs the correct control signal.

[0132] Among them, the key point of whether the thermal management performance meets the design requirements is whether it can meet the design requirements of the thermal management system, that is, whether it can meet the requirements of thermal management performance such as the ability of air conditioning heating and cooling, and whether the ability of battery heat dissipation and insulation can meet the requirements. For example, the passenger compartment has a maximum cooling demand and sets the target temperature to 17 degrees. At this time, the compressor and blower in the air conditioning system both output the maximum speed to meet the demand for rapid cooling. Within the specified time, the temperature of the passenger compartment reaches 17 degrees, which means that the thermal management performance of the air conditioning system meets the design requirements.

[0133] In addition, the present invention further comprises the following steps:

[0134] Step S4, multiple tests and optimization. Multiple tests are performed until all test cases are completed, and then multiple experiments and repeated debugging are performed to confirm the thermal management control system and complete the development and verification of the vehicle-level control strategy and vehicle-level controller.

[0135] Compared with the prior art, in the field of automotive thermal management, the present invention can provide the following beneficial effects for the development and verification of thermal systems:

[0136] 1. More accurately simulate vehicle operating conditions and replace manual input with real environment.

[0137] 2. Simulate the electrical fault of the controlled object.

[0138] 3. It can realize repeated testing, simulate various extreme working conditions or expensive test items in real experimental environments, reduce the development cost of thermal management control, and improve development efficiency.

[0139] 4. It can complement the collaborative capabilities of thermal system control development and testing, realize the development of vehicle-level controllers, and open up the entire development process of thermal management systems

[0140] It can be understood that the same or similar parts of the above embodiments can be referenced to each other, and the contents not described in detail in some embodiments can refer to the same or similar contents in other embodiments.

[0141] Although the embodiments of the present patent have been shown and described above, it can be understood that the above embodiments are exemplary and cannot be understood as limitations of the present invention. Ordinary technicians in this field can change, modify, replace and modify the above embodiments within the scope of the present invention.

Claims

1. A new energy vehicle thermal management control development and verification platform, characterized in that: include: Thermal management control development host computer and experimental data processing system (1), environmental laboratory control system (2), thermal management HIL test system (3), data acquisition system (5) and test object (7); The object under test (7) is an ECU or RCP system; Among them, the thermal management control development host computer and the experimental data processing system (1) are connected to the thermal management HIL test system (3) and the data acquisition system (5) respectively; A thermal management HIL test system (3) is connected to the environmental laboratory control system (2) and the test object (7) respectively; The tested object (7) is connected to the data acquisition system (5); A data acquisition system (5) connected to the environmental laboratory control system (2); The platform is used to execute working mode 1 and working mode 2; When the platform includes a thermal system actuator (8) as a physical object and requires an environmental laboratory (4) to provide a real experimental environment, the platform can execute the following working mode 1: A thermal management HIL test system (3) is connected to the environmental laboratory control system (2) and is used to send a control signal to the environmental laboratory control system (2); An environmental laboratory control system (2) is used to receive a control signal from a thermal management HIL test system (3) to control the environmental laboratory (4); Thermal system sensors (6) and thermal system actuators (8) are located inside the environmental laboratory (4); An environmental laboratory (4) is used to provide a real experimental environment for the test object (7); Thermal system sensor (6) for detecting environmental parameters in the environmental laboratory (4) and then sending them to the tested object (7) and the data acquisition system (5); The object under test (7) is used to receive environmental data sent by the thermal system sensor (6), obtain corresponding control signals according to the existing thermal management control strategy, and then send them to the corresponding thermal system actuator (8) to drive the thermal system actuator (8) to operate; The data acquisition system (5) is connected to the thermal system sensor (6), the test object (7) and the thermal system actuator (8) respectively, and is used to collect the environmental parameters in the environmental laboratory (4) in real time, and send them to the thermal management control development host computer and the experimental data processing system (1), and the thermal management control development host computer and the experimental data processing system (1) judge whether the environmental parameters in the environmental laboratory (4) meet the control requirements; Whether the environmental parameters in the environmental laboratory (4) meet the control requirements, specifically: whether the control requirements of the existing thermal management control strategy on the test object (7) are met, that is, whether the thermal system actuator (8) performs the corresponding action according to the control signal of the thermal system actuator (8); Wherein, regardless of whether the platform includes a thermal system actuator (8) as a physical object, the platform is capable of executing the following working mode 2: A thermal management HIL test system (3) for sending a virtual signal to a test object (7); The object under test (7) is used to analyze the virtual signal according to the thermal management control strategy and the real-time model of the thermal system, obtain the corresponding control signal, and then return it to the thermal management HIL test system (3); The thermal management HIL test system (3) is used to judge the control signal sent back by the test object (7) based on the real-time model of the thermal system it has, and judge whether the control signal sent back by the test object (7) meets the design requirements; Determine whether the control signal sent back by the object under test (7) meets the design requirements, specifically: when the control signal is input into the real-time model of the thermal system in the real-time machine of the thermal management HIL test system (3) and runs, whether it meets the design requirements of the real-time model of the thermal system; The thermal management HIL test system (3) includes a real-time controller; A real-time controller for running a real-time model of the thermal system therein; The thermal management HIL test system (3) is also connected to one end of the fault circuit and the normal circuit respectively through a connection terminal box; The other ends of the fault circuit and the normal circuit are connected to the object under test (7) through a connecting terminal box; Fault loop, used to simulate fault conditions; Fault conditions, including sensor failures, communication fault injection, power fault injection, and thermal system failures; Fault circuits and normal circuits are available for selection, which can realize the normal function test of the thermal management control system and the control function test after a fault occurs.

2. The new energy vehicle thermal management control development and verification platform as claimed in claim 1, characterized in that: Environmental parameters, including temperature, humidity, wind speed, air volume, water temperature and sunlight intensity.

3. The new energy vehicle thermal management control development and verification platform as claimed in claim 1, characterized in that: The real-time thermal management model includes: automobile air conditioning model, battery model, motor model, vehicle model, environmental model and driving model.

4. The new energy vehicle thermal management control development and verification platform as claimed in claim 1, characterized in that: The thermal management control development host computer and the experimental data processing system (1) are connected to the thermal management HIL test system (3) and the data acquisition system (5) through Ethernet. The object under test (7) communicates data with the data acquisition system (5) via CAN.

5. A method for implementing the new energy vehicle thermal management control development and verification platform as claimed in any one of claims 1 to 4, characterized in that: The following steps are involved: Step S1, determining different test operations to be performed according to specific test requirements, whether there is a thermal system actuator (8), and whether an environmental laboratory (4) is required to provide a real experimental environment; Step S2, obtaining corresponding test data by executing the first test operation and the second test operation respectively; The first test operation is performed only when the platform includes a thermal system actuator (8) as a physical object and the environmental laboratory (4) is required to provide a real experimental environment, while the second test operation can be performed regardless of whether the platform includes a thermal system actuator (8) as a physical object; Step S3, test data upload and analysis and processing: upload the test data obtained in step S2 to the thermal management control development host computer and the experimental data processing system (1) for analysis and processing; In step S2, the first test operation includes the following steps: Step S211, building a physical model and configuring an embedded system: in the thermal management HIL test system (3), a physical model of the thermal system is built according to the pre-designed thermal system configuration, and an ECU or RCP system corresponding to the physical thermal system is configured; Step S212, building a thermal management development verification environment: configuring an ECU or RCP system as a test object, connecting the ECU or RCP system with a thermal system sensor (6) and a thermal system actuator (8), and ensuring signal transmission between the thermal system actuator (8) and the thermal system sensor (6) of the ECU or RCP system; At the same time, connect the thermal management HIL test system (3), the thermal management control development host computer and the experimental data processing system (1), the environmental laboratory control system (2) and the data acquisition system (5), and then connect the ECU or RCP system, the thermal system sensor (6) and the thermal system actuator (8) to the entire development and verification platform to complete the construction of the thermal management development and verification environment; Step S213, thermal management test case realization: the thermal management HIL test system (3) directly controls the environmental laboratory control system (2), and according to the requirements of the test case, the environmental laboratory control system (2) allows the environmental laboratory (4) to provide a corresponding experimental environment that simulates the real environment, and the thermal system sensor (6) installed in the environmental laboratory (4) detects the environmental parameters in the environmental laboratory (4), and then sends them to the ECU or RCP system as the test object. The ECU or RCP system then controls the corresponding thermal system actuator (8) according to the pre-stored thermal management control strategy; Step S214, test data collection: the data collection system (5) receives the signal output from the thermal system actuator (8) installed in the environmental laboratory (4) and the signal collected by the thermal system sensor (6) through the CAN communication method, completes the collection of test data, and the data collection system (5) sends the collected environmental parameters in the environmental laboratory (4) to the thermal management control development host computer and the experimental data processing system (1), and the thermal management control development host computer and the experimental data processing system (1) determine whether the environmental parameters in the environmental laboratory (4) meet the control requirements; Whether the environmental parameters in the environmental laboratory (4) meet the control requirements, specifically: whether the control requirements of the existing thermal management control strategy on the test object (7) are met, that is, whether the thermal system actuator (8) performs the corresponding action according to the control signal of the thermal system actuator (8); In step S2, the second test operation includes the following steps: Step S221, building a real-time model of the thermal system: according to the test requirements, for different thermal management function tests, corresponding real-time simulation models of the thermal system are built respectively; Step S222, determining whether a fault test is required: if a fault test is required, adding a thermal management fault loop to the test link; if a fault test is not required, selecting a conventional loop for testing; Step S223, test case implementation, obtaining test data: the thermal management HIL test system (3) sends a virtual signal to the ECU or RCP system of the object under test, and after receiving the virtual signal, the ECU or RCP system sends a corresponding control signal according to the existing control strategy, and then the thermal management HIL test system (3) receives the control signal of the ECU or RCP system and determines whether the control signal meets the design requirements; Determine whether the control signal sent back by the tested object (7) meets the design requirements, specifically: when the control signal is input into the real-time model of the thermal system in the real-time machine of the thermal management HIL test system (3), whether it meets the design requirements of the real-time model of the thermal system.

Images