Whole vehicle power hardware-in-loop simulation test system and method under P2.5 +P4 hybrid architecture

Abstract

The invention discloses a whole vehicle power hardware-in-the-loop simulation test system and method under a P2.5 + P4 hybrid architecture. The whole vehicle power hardware-in-the-loop simulation test system comprises a controller, a test cabinet and an upper computer system, the hybrid power gearbox control system is electrically connected with the high-voltage control system; the test cabinet is electrically connected with the hybrid power gearbox control system, the high-voltage control system and the upper computer system; the upper computer system comprises a management module, a signal interface module, a controller interface module and a virtual simulation vehicle module, the management module is connected with the test cabinet and the signal interface module, and the signal interface module is used for realizing signal interaction between the controller interface module and the management module; the controller interface module is connected with the signal interface module, the Soft ECU module and the power simulation module. Standardized development of the power simulation test system is realized, the modular design supports rapid adaptation of different vehicle type platforms and power architectures, and repeated development is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of vehicles, and more particularly to a whole vehicle power hardware-in-the-loop simulation test system and method under a P2.5+P4 hybrid architecture. BACKGROUND

[0002] With the development of hybrid electric vehicle (HEV) technology, the complexity of its power system has significantly improved, involving the coordinated control of multiple components such as engines, motors, batteries, and transmission systems. Traditional real vehicle testing has problems such as high cost, long cycle, and high risk. Hardware-in-the-loop simulation (HIL) technology replaces real vehicle components with real-time simulation models, which can achieve efficient and safe controller function verification, improve controller development efficiency, and become an important means of verifying whole vehicle controller functions.

[0003] Currently, a hybrid power system including real components such as engines, motors, and batteries is simulated on a physical test bench, and a real-time simulation machine is used to simulate vehicle operating conditions to verify the function logic of HTCU and HVCU. However, the hardware cost of the above-mentioned method is high, multiple dynamometers and load devices need to be configured, and the test environment is strongly bound to the hardware, making it difficult to adapt to different hybrid architectures (such as P0 / P2.5 / P4), and it is also unable to realize complex fault simulation, controller performance testing under extreme conditions, and automatic testing.

[0004] Therefore, how to provide a whole vehicle power hardware-in-the-loop simulation test system and method under a P2.5+P4 hybrid architecture has become a technical problem that needs to be solved in the field. SUMMARY

[0005] The purpose of the present application is to provide a new technical solution for a whole vehicle power hardware-in-the-loop simulation test system and method under a P2.5+P4 hybrid architecture.

[0006] According to a first aspect of the present application, a whole vehicle power hardware-in-the-loop simulation test system under a P2.5+P4 hybrid architecture is provided, comprising: a controller, a test cabinet, and an upper computer system;

[0007] The controller comprises a hybrid power transmission control system and a high-voltage control system, and the hybrid power transmission control system is electrically connected to the high-voltage control system;

[0008] The test cabinet is electrically connected to the hybrid power transmission control system, the high-voltage control system, and the upper computer system;

[0009] The host computer system includes a management module, a signal interface module, a controller interface module, and a virtual simulation vehicle module. The virtual simulation vehicle module includes a Soft ECU module and a power simulation module. The management module is connected to the test cabinet and the signal interface module. The signal interface module is used to realize signal interaction between the controller interface module and the management module. The controller interface module is connected to the signal interface module, the Soft ECU module, and the power simulation module respectively. The Soft ECU module is used to construct a virtual simulation vehicle and road model, and the power simulation module is used to realize power closed-loop simulation in the virtual road model.

[0010] Optionally, the management module includes Configuration Desk, Model Desk, Control Desk, Automation Desk, and SCALEXIO.

[0011] Optionally, the signal interface module includes a CAN signal interface, a LIN signal interface, and a hard-wired signal interface;

[0012] The test cabinet includes a real-time machine unit, a bus board unit, and an I / O board unit.

[0013] Optionally, the controller interface module includes a gearbox control interface unit and a high-voltage control interface unit. The high-voltage control interface unit is connected to the signal interface module and the Soft ECU module, respectively, and the gearbox control interface unit is connected to the signal interface module and the power simulation module, respectively.

[0014] Optionally, the Soft ECU module includes a high-voltage power-on / off unit, an anti-theft authentication unit, a battery unit, an IPB unit, and a GSM unit.

[0015] Optionally, the power simulation module includes a power analysis unit, a gear analysis unit, a drive unit, a transmission unit, and a vehicle dynamics unit. The power analysis unit, the drive unit, and the vehicle dynamics unit are connected to the gearbox control interface unit. The drive unit is connected to the power analysis unit and the transmission unit, and the transmission unit is connected to the vehicle dynamics unit. The gear analysis unit is connected to the high-pressure control interface unit and the transmission unit, and the transmission unit is connected to the power analysis unit.

[0016] According to a second aspect of the present invention, a vehicle powertrain hardware-in-the-loop simulation test method under a P2.5+P4 hybrid architecture is provided, comprising the following steps:

[0017] Step S1: Establish a standardized mapping relationship library for hardware channels in the hardware-in-the-loop simulation cabinet;

[0018] Step S2: Establish a parameterizable Simulink dynamic virtual simulation model;

[0019] Step S3: Configure the hardware channels of the simulation cabinet and the models of each subsystem in the model library according to the actual hardware interface and software function definition of the controller, and build the simulation test bench.

[0020] Step S4: Conduct bench and controller interface testing;

[0021] Step S5: Generate automated test cases based on functional specifications;

[0022] Step S6: Perform real-time closed-loop verification in a real hardware-in-the-loop simulation test environment to monitor whether the outputs of the hybrid power transmission control system and the high-voltage control system meet the design functional specifications.

[0023] Step S7: Based on the software version changes of the hybrid transmission control system and high-voltage control system, maintain the current test bench, adjust the hardware channels and model selection, and conduct multiple rounds of regression testing.

[0024] Optionally, in step S4, bench and controller interface testing is performed to test whether all configuration channels of the test cabinet, all hardwired controllers, and CAN / LIN interface inputs are consistent with the design.

[0025] The beneficial effects of this invention are as follows:

[0026] This invention electrically connects the hybrid power transmission control system to the high-voltage control system; electrically connects the test cabinet to the hybrid power transmission control system, the high-voltage control system, and the host computer system; and connects the management module to the test cabinet and the signal interface module. The signal interface module is used to realize signal interaction between the controller interface module and the management module. The controller interface module is connected to the signal interface module, the Soft ECU module, and the power simulation module respectively. This invention achieves standardized development of the power simulation test system, and the modular design supports rapid adaptation to different vehicle platforms and power architectures (such as pure electric, hybrid, and fuel cell), reducing redundant development.

[0027] Other features and advantages of the invention will become clear from the following detailed description of exemplary embodiments of the invention with reference to the accompanying drawings. Attached Figure Description

[0028] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments of the invention and, together with their description, serve to explain the principles of the invention.

[0029] Figure 1This is a structural diagram of the vehicle power hardware-in-the-loop simulation test system under the P2.5+P4 hybrid architecture of the present invention;

[0030] Figure 2 This is a flowchart of the vehicle power hardware-in-the-loop simulation test under the P2.5+P4 hybrid architecture of the present invention. Detailed Implementation

[0031] Various exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that, unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention.

[0032] The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the invention or its application or use.

[0033] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and equipment should be considered part of the specification.

[0034] In all the examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values.

[0035] like Figure 1 As shown, this embodiment of the invention provides a vehicle power hardware-in-the-loop simulation test system under a P2.5+P4 hybrid architecture, including: a controller, a test cabinet, and a host computer system.

[0036] The controller includes a hybrid power transmission control system (HTCU) and a high-voltage control system (HVCU), which are electrically connected. Specifically, the HTCU and HVCU are capable of signal interaction.

[0037] The test cabinet is electrically connected to the hybrid power transmission control system, the high-voltage control system, and the host computer system.

[0038] The host computer system includes a management module, a signal interface module, a controller interface module, and a virtual simulation vehicle module. The virtual simulation vehicle module includes a Soft ECU module and a power simulation module. The management module is connected to the test cabinet and the signal interface module. The signal interface module is used to realize signal interaction between the controller interface module and the management module. The controller interface module is connected to the signal interface module, the Soft ECU module, and the power simulation module respectively. The Soft ECU module is used to build virtual simulation vehicle and road models, and the power simulation module is used to realize power closed-loop simulation in the virtual road model.

[0039] Specifically, firstly, a standardized mapping library of hardware channels for the hardware-in-the-loop simulation cabinet is established using the hybrid power transmission control system (HTCU) and the high-voltage control system (HVCU). Then, a parameterizable Simulink dynamic virtual simulation model is built using the Soft ECU module. Based on the configuration of the hardware channels in the hardware-in-the-loop simulation cabinet and the models of each subsystem in the model library, including the signal interface module, controller interface module, and test cabinet, a simulation test bench is constructed. Next, using multimeters and CANOE testing tools, all configuration channels of the test cabinet, all hardwired controllers, and CAN / LIN interface inputs are tested to ensure they match the design. If they do, real-time closed-loop verification can be performed in a real hardware-in-the-loop simulation test environment to monitor whether the outputs of the hybrid power transmission control system and the high-voltage control system meet the design functional specifications.

[0040] This invention utilizes a controller comprising a hybrid power transmission control system and a high-voltage control system, with the hybrid power transmission control system electrically connected to the high-voltage control system. The test cabinet is electrically connected to the hybrid power transmission control system, the high-voltage control system, and the host computer system. A management module is connected to the test cabinet and a signal interface module, which enables signal interaction between the controller interface module and the management module. The controller interface module is connected to the signal interface module, the Soft ECU module, and the power simulation module, respectively. This invention achieves standardized development of the power simulation test system, and its modular design supports rapid adaptation to different vehicle platforms and power architectures (such as pure electric, hybrid, and fuel cell vehicles), reducing redundant development.

[0041] In one embodiment of the vehicle power hardware-in-the-loop simulation test system under the P2.5+P4 hybrid architecture of the present invention, the management module includes Configuration Desk, Model Desk, Control Desk, Automation Desk and SCALEXIO.

[0042] It should be noted that all of the above software systems were developed by Dspace.

[0043] In one embodiment of the vehicle power hardware-in-the-loop simulation test system under the P2.5+P4 hybrid architecture of the present invention, the signal interface module includes a CAN signal interface, a LIN signal interface, and a hardwired signal interface.

[0044] The test cabinet includes real-time machine units, bus board units, and I / O board units, which facilitates the installation of various hardware and software components.

[0045] Specifically, the signal interface module includes all hardwired data, CAN signal interfaces, and LIN signal interfaces of the hybrid power transmission control system (HTCU) and high-voltage control system (HVCU), such as sensor models, water pump models, electronic switch models, solenoid valve models, three-way valve models (LIN signal), and CAN signal models, to realize signal interaction between the controller interface module and the management module software.

[0046] It should be noted that the real-time machine unit, bus board unit, and I / O board unit are existing technologies and will not be described in detail here.

[0047] Furthermore, the controller interface module includes a gearbox control interface unit and a high-voltage control interface unit. The high-voltage control interface unit is connected to the signal interface module and the Soft ECU module, respectively, and the gearbox control interface unit is connected to the signal interface module and the power simulation module, respectively.

[0048] In one embodiment of the vehicle power hardware-in-the-loop simulation test system under the P2.5+P4 hybrid architecture of the present invention, the Soft ECU module includes a high-voltage power-on / off unit, an anti-theft authentication unit, a battery unit, an IPB unit, and a GSM unit.

[0049] Specifically, the Soft ECU model encompasses other controllers or functional logic models related to the hybrid transmission control system (HTCU) and high voltage control system (HVCU), such as battery unit, IPB unit, GSM unit, high and low voltage power-on / off units, and anti-theft authentication unit, and may also include other units, without limitation.

[0050] In one embodiment of the vehicle power hardware-in-the-loop simulation test system under the P2.5+P4 hybrid architecture of the present invention, the power simulation module includes a power analysis unit, a gear analysis unit, a drive unit, a transmission unit, and a vehicle dynamics unit. The power analysis unit, drive unit, and vehicle dynamics unit are connected to the gearbox control interface unit. The drive unit is connected to the power analysis unit and the transmission unit, and the transmission unit is connected to the vehicle dynamics unit. The gear analysis unit is connected to the high-voltage control interface unit and the transmission unit, and the transmission unit is connected to the power analysis unit.

[0051] Specifically, the power simulation module realizes the power simulation of the hybrid transmission control system (HTCU) and the high-voltage control system (HVCU), issues commands to drive the output torque of the hybrid transmission control system (HTCU) and the high-voltage control system (HVCU), and at the same time, each system transmits the torque to the wheel ends of the simulated vehicle and realizes the power closed-loop simulation in the virtual road model. The main gear analysis unit realizes the power-related signals released by the high-voltage control system (HVCU) and transmits them to the drive unit.

[0052] The power analysis unit analyzes the gear-related signals released by the hybrid transmission control unit (HTCU) and transmits them to the transmission unit.

[0053] The drive unit includes an engine model, a battery model, and a P2.5+P4 motor model. The drive unit transmits signals such as torque, voltage, and current to the high-voltage control interface unit, realizing closed-loop simulation of the power transmitted by the high-voltage control system (HVCU) and the speed feedback from the transmission unit to obtain real-time closed-loop torque, bus voltage, and current.

[0054] The transmission unit includes an engine crankshaft model, a clutch model, a P2.5+P4 motor reducer model, and a main reducer model. The transmission unit transmits signals such as the output shaft speed of the gearbox and the actual gear position to the gearbox control interface unit. It also converts the torque transmitted by the drive unit into wheel-end torque and moment of inertia, which are then transmitted to the vehicle dynamics unit. In addition, it converts the vehicle speed signal fed back by the vehicle dynamics unit into engine and motor speeds, which are then transmitted to the drive unit.

[0055] The vehicle dynamics unit includes wheel models, driving force models, drag models, braking models, and virtual road models. Through the constructed virtual simulation vehicle and road models, it dynamically controls operation in real-time in virtual vehicle mode, and transmits relevant parameters (vehicle speed, driving force, etc.) generated during the process back to the controller interface module and transmission unit. Furthermore, the vehicle dynamics unit also transmits relevant signals such as vehicle speed, driving force, braking force, and drag to the high-voltage control interface unit.

[0056] This invention establishes a hardware-in-the-loop simulation test system for vehicle powertrain, enabling standardized development of the powertrain simulation test system. The modular design supports rapid adaptation to different vehicle platforms and powertrain architectures (such as pure electric, hybrid, and fuel cell), reducing redundant development.

[0057] This invention also supports automated test scripts and a standardized test case library, which can quickly cover multiple scenarios (such as high and low temperatures, plateau environments) and multiple operating conditions (such as rapid acceleration, energy recovery), accelerating the iteration cycle; it can reproduce extreme conditions that are difficult to achieve in reality (such as -40℃ low temperature, motor overload failure), verify the robustness of the system, and expand the test boundaries.

[0058] Furthermore, a hardware-in-the-loop simulation device can simultaneously verify different subsystems (such as the hybrid power transmission control system (HTCU) and the high-voltage control system (HVCU)), possessing parallel testing capabilities, shortening the development cycle, and improving testing efficiency and coverage.

[0059] Moreover, this invention enables rapid switching of test environments at different test stages, meeting the closed-loop verification requirements of different subsystems of the controller software.

[0060] According to a second aspect of the invention, such as Figure 2 As shown, a hardware-in-the-loop simulation test method for the vehicle powertrain under the P2.5+P4 hybrid architecture is provided, including the following steps:

[0061] Step S1: Establish a standardized mapping library for hardware channels in the hardware-in-the-loop simulation cabinet. Specifically, based on the standardized interface definitions of the basic software layer of the hybrid power transmission control system (HTCU) and high-voltage control system (HVCU), establish a standardized mapping library for hardware channels in the hardware-in-the-loop simulation cabinet, such as using dSPACE ConfigurationDesk. For example: the CAN / LIN communication interface is configured with fixed cabinet channels (e.g., CAN1 - channel group A, LIN1 - channel group B); the power drive interface (PWM / HSD) uses a unified hardware board (e.g., the power drive module of dSPACE SCALEXIO); and the sensor input interface (ADC / DIG) is configured with a standardized signal conditioning unit.

[0062] Step S2: Establish a parameterizable Simulink dynamic virtual simulation model;

[0063] Specifically, it mainly consists of three major modules: signal interface module, controller interface module, and virtual simulation vehicle module. It covers simulation of all hard-wired interfaces such as speed, oil temperature sensor, accelerator pedal, motor, battery water pump, etc., CAN bus simulation, LIN master node simulation, drive system (engine, motor), power battery system, transmission system, vehicle dynamics, and other virtual vehicle models.

[0064] Step S3: Configure the hardware channels of the simulation cabinet and the models of each subsystem in the model library according to the actual hardware interface and software function definition of the controller, and build the simulation test bench.

[0065] Specifically, all system nodes except for the hybrid power transmission control system (HTCU) and high-voltage control system (HVCU) controllers are implemented using rack simulation. The complete hardware-in-the-loop test bench includes the HVCU controller, the HVCU controller, the hardware-in-the-loop simulation (HIL) rack, and the host computer. The HVCU controllers are connected to each other via hardwired and CAN bus lines, and the remaining hardwired connections are also made to the HIL rack.

[0066] Hardware-in-the-loop (HIL) cabinets include I / O, communication boards, and real-time machines.

[0067] Step S4: Conduct bench and controller interface testing;

[0068] Step S5: Generate automated test cases based on functional specifications;

[0069] Step S6: Perform real-time closed-loop verification in a real hardware-in-the-loop simulation test environment to monitor whether the outputs of the hybrid power transmission control system and the high-voltage control system meet the design functional specifications.

[0070] Specifically, the hardware-in-the-loop (HIL) simulation cabinet real-time system simulates vehicle acceleration, simulating an accelerator pedal opening of 50%, and collects the output torque of the motor and engine of the hybrid transmission control system and the output gear of the high-voltage control system. The power calculation system calculates the output shaft torque of the transmission, and transmits the torque in the virtual simulation model through the simulation drive unit and transmission unit to the vehicle dynamics unit to calculate the vehicle speed. The torque is then fed back to the hybrid transmission control system (HTCU) to form a dynamic closed loop, and the accelerator pedal, the gear of the hybrid transmission control system (HTCU), the output torque of the high-voltage control system (HVCU), and the simulated vehicle speed are monitored in real time and compared with the power curve defined in the functional specifications.

[0071] If the measured torque and gear position conform to the design specifications, then the design specifications are deemed met. This closed-loop verification process covers the entire chain from signal input to logic judgment to execution output, ensuring that the behavior of the hybrid power transmission control system (HTCU) and the high-voltage control system (HVCU) is consistent with the design.

[0072] Step S7: Based on the software version changes of the hybrid transmission control system and high-voltage control system, maintain the current test bench, adjust the hardware channels and model selection, and conduct multiple rounds of regression testing.

[0073] In one embodiment of the vehicle power hardware-in-the-loop simulation test method under the P2.5+P4 hybrid architecture of the present invention, in step S4, the bench and controller interface test is carried out by using tools such as multimeters and CANOE test tools to test whether all configuration channels of the test cabinet, all hardwires of the controller, and CAN / LIN line interface inputs are consistent with the design.

[0074] While specific embodiments of the invention have been described in detail by way of examples, those skilled in the art should understand that the examples are for illustrative purposes only and not intended to limit the scope of the invention. Those skilled in the art should understand that modifications can be made to the above embodiments without departing from the scope and spirit of the invention. The scope of the invention is defined by the appended claims.

Claims

1. A hardware-in-the-loop simulation test system for vehicle powertrain under a P2.5+P4 hybrid architecture, characterized in that, include: Controller, test cabinet, and host computer system; The controller includes a hybrid power transmission control system and a high-voltage control system, wherein the hybrid power transmission control system is electrically connected to the high-voltage control system. The test cabinet is electrically connected to the hybrid power transmission control system, the high voltage control system, and the host computer system. The host computer system includes a management module, a signal interface module, a controller interface module, and a virtual simulation vehicle module. The virtual simulation vehicle module includes a Soft ECU module and a power simulation module. The management module is connected to the test cabinet and the signal interface module. The signal interface module is used to realize signal interaction between the controller interface module and the management module. The controller interface module is connected to the signal interface module, the Soft ECU module, and the power simulation module respectively. The Soft ECU module is used to construct a virtual simulation vehicle and road model, and the power simulation module is used to realize power closed-loop simulation in the virtual road model.

2. The vehicle powertrain hardware-in-the-loop simulation test system under the P2.5+P4 hybrid architecture according to claim 1, characterized in that, The management module includes Configuration Desk, Model Desk, Control Desk, Automation Desk, and SCALEXIO.

3. The vehicle powertrain hardware-in-the-loop simulation test system under the P2.5+P4 hybrid architecture according to claim 1, characterized in that, The signal interface module includes a CAN signal interface, a LIN signal interface, and a hard-wired signal interface; The test cabinet includes a real-time machine unit, a bus board unit, and an I / O board unit.

4. The vehicle powertrain hardware-in-the-loop simulation test system under the P2.5+P4 hybrid architecture according to claim 1, characterized in that, The controller interface module includes a gearbox control interface unit and a high-voltage control interface unit. The high-voltage control interface unit is connected to the signal interface module and the Soft ECU module, respectively. The gearbox control interface unit is connected to the signal interface module and the power simulation module, respectively.

5. The vehicle powertrain hardware-in-the-loop simulation test system under the P2.5+P4 hybrid architecture according to claim 1, characterized in that, The Soft ECU module includes a high-voltage power-on / off unit, an anti-theft authentication unit, a battery unit, an IPB unit, and a GSM unit.

6. The vehicle powertrain hardware-in-the-loop simulation test system under the P2.5+P4 hybrid architecture according to claim 4, characterized in that, The power simulation module includes a power analysis unit, a gear analysis unit, a drive unit, a transmission unit, and a vehicle dynamics unit. The power analysis unit, the drive unit, and the vehicle dynamics unit are connected to the gearbox control interface unit. The drive unit is connected to the power analysis unit and the transmission unit, and the transmission unit is connected to the vehicle dynamics unit. The gear analysis unit is connected to the high-pressure control interface unit and the transmission unit, and the transmission unit is connected to the power analysis unit.

7. A hardware-in-the-loop simulation test method for vehicle powertrain under a P2.5+P4 hybrid architecture, characterized in that, Includes the following steps: Step S1: Establish a standardized mapping relationship library for hardware channels in the hardware-in-the-loop simulation cabinet; Step S2: Establish a parameterizable Simulink dynamic virtual simulation model; Step S3: Configure the hardware channels of the simulation cabinet and the models of each subsystem in the model library according to the actual hardware interface and software function definition of the controller, and build the simulation test bench. Step S4: Conduct bench and controller interface testing; Step S5: Generate automated test cases based on functional specifications; Step S6: Perform real-time closed-loop verification in a real hardware-in-the-loop simulation test environment to monitor whether the outputs of the hybrid power transmission control system and the high-voltage control system meet the design functional specifications. Step S7: Based on the software version changes of the hybrid transmission control system and high-voltage control system, maintain the current test bench, adjust the hardware channels and model selection, and conduct multiple rounds of regression testing.

8. The vehicle powertrain hardware-in-the-loop simulation test method under the P2.5+P4 hybrid architecture according to claim 7, characterized in that, In step S4, bench and controller interface testing is conducted to test whether all configuration channels of the test cabinet, all hardwired controllers, and CAN / LIN interface inputs are consistent with the design.

Images