Load simulation testing device
By designing a load simulation test device, using a load module to simulate engine components in the load box, the problem of high actuator cost and difficulty in using real actuator simulation in HIL test is solved, and the closed loop of controller and hardware in-loop testing is realized. Reduced development costs and cycles.
Patent Information
- Application Number
- CN202421414579.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-06-19
- Publication Date
- 2025-02-21
- Estimated Expiration
- 2034-06-19
AI Technical Summary
Existing actuators are costly and it is difficult to simulate with real actuators in HIL tests.
A load simulation test device is designed, including a load box, a hardware in-loop test cabinet and a controller. The load box simulates real engine components through load modules (such as load resistors, inductors, blocking resistors and switch modules) to replace real engine components. actuator.
The closed loop of controller and hardware in-loop testing is realized, reducing development costs and cycles, and solving the problem that nonlinear loads are difficult to simulate and HIL cannot be closed loop without real loads.
Smart Images
Figure CN222514683U_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the field of engine testing, and in particular, to a load simulation testing device. Background Art
[0002] Hardware-in-the-loop (HIL) simulation testing is a very important part of the controller development process. It can reduce the number of bench and real vehicle road tests, shorten the development cycle, reduce costs, and improve the software quality of the controller. On the HIL platform, it is necessary to simulate sensors and various actuators. Sensors can be output through HIL pins, but various actuators (such as throttles, EGR valves, bypass valves, pressure regulating valves, etc. related to engine controllers) are often expensive, and many samples are in short supply, so it is often difficult to coordinate them to HIL as loads. Utility Model Content
[0003] The main purpose of the present application is to provide a load simulation test device to solve the problem that the existing actuators are relatively expensive and it is difficult to simulate with real actuators in HIL testing.
[0004] In order to achieve the above-mentioned purpose, according to one aspect of the present application, a load simulation test device is provided, comprising: a load box having a first input end, a second input end and an output end, the load box being used to simulate real engine components; a hardware-in-the-loop test cabinet having an input end and a first output end, the input end of the hardware-in-the-loop test cabinet being electrically connected to the output end of the load box, the hardware-in-the-loop test cabinet being used to receive a feedback signal of the load box to test the load box, and calculating and processing the feedback signal to obtain a voltage signal; a controller having an input end, a first output end and a second output end, the input end of the controller being electrically connected to the first output end of the hardware-in-the-loop test cabinet and receiving the voltage signal emitted by the hardware-in-the-loop test cabinet, the first output end of the controller being electrically connected to the first input end of the load box, the second output end of the controller being electrically connected to the second input end of the load box, and the controller being used to send a drive signal to the load box to drive the load box.
[0005] Furthermore, the load box also includes: at least one load module, having a first input end, a second input end and an output end, the first input end of the load module is electrically connected to the first output end of the controller, the second input end of the load module is electrically connected to the second output end of the controller, and the output end of the load module is electrically connected to the input end of the hardware-in-the-loop test cabinet.
[0006] Furthermore, in the case where there are multiple load modules, the load modules are not connected to each other, the hardware-in-the-loop test cabinet has multiple input terminals, the controller has multiple first output terminals and multiple second output terminals, the number of input terminals of the hardware-in-the-loop test cabinet, the number of first output terminals of the controller and the number of second output terminals of the controller are the same, a group of corresponding first output terminals of the controller and second output terminals of the controller are used to send the drive signal to a corresponding load module, and the input terminal of the hardware-in-the-loop test cabinet is used to receive the feedback signal of the corresponding load module.
[0007] Furthermore, the load module includes: a load resistor having a first end and a second end, the first end of the load resistor being electrically connected to the input end of the hardware-in-the-loop test cabinet and the first output end of the controller respectively, and the second end of the load resistor being electrically connected to the second output end of the controller.
[0008] Furthermore, the load module also includes: an inductor having a first end and a second end, the first end of the inductor being electrically connected to the input end of the hardware-in-the-loop test cabinet and the first output end of the controller respectively, and the second end of the inductor being electrically connected to the first end of the load resistor.
[0009] Furthermore, the load module also includes: a blocking resistor having a first end and a second end, the first end of the blocking resistor being electrically connected to the first end of the load resistor, the input end of the hardware-in-the-loop test cabinet and the first output end of the controller, and the second end of the blocking resistor being electrically connected to the second end of the load resistor and the second output end of the controller.
[0010] Furthermore, the load module also includes: a switch module having a first end and a second end, the first end of the switch module being electrically connected to the first end of the load resistor, the input end of the hardware-in-the-loop test cabinet and the first output end of the controller respectively, and the second end of the switch module being electrically connected to the first end of the blocking resistor.
[0011] Furthermore, the hardware-in-the-loop test cabinet further has a second output end, and the switch module further has a control end, and the control end of the switch module is electrically connected to the second output end of the hardware-in-the-loop test cabinet.
[0012] Furthermore, the switch module is a mechanical switch or a transistor.
[0013] Furthermore, the hardware-in-the-loop test cabinet also includes a real-time simulation chip, which has an input pin and a first output pin. The input pin of the real-time simulation chip is electrically connected to the output end of the load box, and the first output pin of the real-time simulation chip is electrically connected to the input end of the controller.
[0014] Applying the technical solution of the present application, the load simulation test device includes: a load box, which is used to simulate real engine components; a hardware-in-the-loop test cabinet, the input end of the hardware-in-the-loop test cabinet is electrically connected to the output end of the load box, the hardware-in-the-loop test cabinet is used to receive the feedback signal of the load box to test the load box, and calculate and process the feedback signal to obtain a voltage signal; a controller, the input end of the controller is electrically connected to the first output end of the hardware-in-the-loop test cabinet and receives the voltage signal sent by the hardware-in-the-loop test cabinet, the first output end of the controller is electrically connected to the first input end of the load box, the second output end of the controller is electrically connected to the second input end of the load box, and the controller is used to send a drive signal to the load box to drive the load box. The device simulates the load through the load box, replaces the real actuator, can simulate the real opening position, switch and other states of the valve, realizes the closed loop of the controller and the hardware-in-the-loop test, reduces the development cost, shortens the development cycle, not only solves the problem that nonlinear loads are difficult to simulate and HIL cannot be closed without real loads, but also solves the problem that the existing actuators are expensive and difficult to simulate with real actuators in HIL testing. BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The drawings constituting part of the present application are used to provide a further understanding of the present application. The exemplary embodiments and descriptions of the present application are used to explain the present application and do not constitute an improper limitation on the present application. In the drawings:
[0016] Figure 1 A schematic diagram of the structure of a load simulation test device provided according to an embodiment of the present application is shown;
[0017] Figure 2 A schematic structural diagram of a load simulation test device having multiple load modules provided according to an embodiment of the present application is shown;
[0018] Figure 3 A schematic structural diagram of a load simulation test device having a load module provided according to an embodiment of the present application is shown;
[0019] Figure 4 A schematic structural diagram of another load simulation test device provided according to an embodiment of the present application is shown;
[0020] Figure 5A schematic structural diagram of another load simulation test device provided according to an embodiment of the present application is shown.
[0021] The above drawings include the following reference numerals:
[0022] 100. load box; 110. load module; 111. load resistor; 112. inductor; 113. stall resistor; 114. switch module; 200. hardware-in-the-loop test cabinet; 220. real-time simulation chip; 300. controller. DETAILED DESCRIPTION
[0023] It should be noted that the following detailed descriptions are illustrative and are intended to provide further explanation of the present application. Unless otherwise specified, all technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art to which the present application belongs.
[0024] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.
[0025] It should be understood that when an element (such as a layer, film, region, or substrate) is described as being "on" another element, the element may be directly on the other element, or there may be intermediate elements. Moreover, in the specification and claims, when an element is described as being "connected" to another element, the element may be "directly connected" to the other element, or "connected" to the other element through a third element.
[0026] For the convenience of description, some nouns or terms involved in the embodiments of the present application are explained below:
[0027] Hardware-in-the-loop: Hardware-in-the-loop, referred to as HIL, is a hardware-in-the-loop simulation test system. It simulates the operating environment of the object under test by building a simulation model of the controlled object, connects with the controller IO through a real IO interface, completes IO transmission and reception, and enables the controller to judge that it is in a real environment. A system is used to conduct comprehensive and systematic testing of the controller under test.
[0028] Load box: A device that can simulate actual load behavior. It can simulate various loads. The load box can receive control signals from the control unit and generate corresponding load responses based on these signals. The HIL device calculates physical values such as flow, temperature, and pressure based on the model and converts them into electrical values such as voltage and current, which are connected to the corresponding pins of the controller through the load box.
[0029] As introduced in the background technology, the existing hardware-in-the-loop simulation test requires simulation sensors and various actuators. The sensors can be output through the HIL pins, but various actuators (such as the throttle, EGR valve, bypass valve, pressure regulating valve, etc. related to the engine controller) are often expensive, and many samples are in short supply, and are often difficult to coordinate to HIL for use as loads. In order to solve the problem that the existing actuators are expensive and it is difficult to simulate with real actuators in HIL testing, the present application proposes a load simulation test device.
[0030] Figure 1 is a structural diagram of a load simulation test device according to an embodiment of the present application, such as Figure 1 As shown, the load simulation test device includes: a load box 100, having a first input end, a second input end and an output end, and the load box 100 is used to simulate real engine components; a hardware-in-the-loop test cabinet 200, having an input end and a first output end, and the input end of the hardware-in-the-loop test cabinet 200 is electrically connected to the output end of the load box 100, and the hardware-in-the-loop test cabinet 200 is used to receive the feedback signal of the load box 100 to test the load box 100, and calculate and process the feedback signal to obtain a voltage signal; a control The controller 300 has an input end, a first output end and a second output end. The input end of the controller 300 is electrically connected to the first output end of the hardware-in-the-loop test cabinet 200 and receives the voltage signal emitted by the hardware-in-the-loop test cabinet 200. The first output end of the controller 300 is electrically connected to the first input end of the load box 100. The second output end of the controller 300 is electrically connected to the second input end of the load box 100. The controller 300 is used to send a driving signal to the load box 100 to drive the load box 100.
[0031] The above-mentioned load simulation test device of the present application includes: a load box, which is used to simulate real engine components; a hardware-in-the-loop test cabinet, the input end of the hardware-in-the-loop test cabinet is electrically connected to the output end of the load box, the hardware-in-the-loop test cabinet is used to receive the feedback signal of the load box to test the load box, and calculate and process the feedback signal to obtain a voltage signal; a controller, the input end of the controller is electrically connected to the first output end of the hardware-in-the-loop test cabinet and receives the voltage signal sent by the hardware-in-the-loop test cabinet, the first output end of the controller is electrically connected to the first input end of the load box, the second output end of the controller is electrically connected to the second input end of the load box, and the controller is used to send a drive signal to the load box to drive the load box. The device simulates the load through the load box, replaces the real actuator, can simulate the real opening position, switch and other states of the valve, realizes the closed loop of the controller and the hardware-in-the-loop test, reduces the development cost, shortens the development cycle, not only solves the problem that nonlinear loads are difficult to simulate and HIL cannot be closed without real loads, but also solves the problem that the existing actuators are expensive and difficult to simulate with real actuators in HIL tests.
[0032] In some embodiments, Figure 2 As shown, the load box 100 further includes: at least one load module 110, having a first input end, a second input end and an output end, the first input end of the load module 110 being electrically connected to the first output end of the controller 300, the second input end of the load module 110 being electrically connected to the second output end of the controller 300, and the output end of the load module 110 being electrically connected to the input end of the hardware-in-the-loop test cabinet 200.
[0033] In this example, a load module is used to simulate an actuator, such as a throttle valve, EGR valve, bypass valve, pressure regulating valve, etc. related to an engine controller. The load box includes multiple load modules that can simulate and test multiple different actuators at the same time to replace the real load.
[0034] In some instances, such as Figure 2 As shown, in the case where there are multiple load modules 110, the load modules 110 are not connected to each other, the hardware-in-the-loop test cabinet 200 has multiple input terminals, and the controller 300 has multiple first output terminals and multiple second output terminals. The number of input terminals of the hardware-in-the-loop test cabinet 200, the number of first output terminals of the controller 300 and the number of second output terminals of the controller 300 are the same, a group of corresponding first output terminals of the controller 300 and the second output terminals of the controller 300 are used to send the driving signal to a corresponding load module 110, and the input terminal of the hardware-in-the-loop test cabinet 200 is used to receive the feedback signal of the corresponding load module 110.
[0035] In this example, multiple load modules are used to simulate different actuators, and controllers are used to control each load module for testing. A set of corresponding first output terminals and second output terminals of the controller are used to exchange information with a load module, and the hardware-in-the-loop test cabinet receives feedback signals sent by different load modules. In this way, multiple different actuators can be simulated and tested at the same time to replace the real load.
[0036] In some instances, such as Figure 3 As shown, the load module 110 includes: a load resistor 111 having a first end and a second end, the first end of the load resistor 111 being electrically connected to the input end of the hardware-in-the-loop test cabinet 200 and the first output end of the controller 300 respectively, and the second end of the load resistor 111 being electrically connected to the second output end of the controller 300.
[0037] In this example, a load resistor is used to simulate the actuator. The resistance of the load resistor is selected according to the load characteristics of the actuator to be simulated by the resistor, and there is no need to purchase a real load. The controller is used to output PWM or H-bridge signals to drive the load resistor, and the HIL is used to collect the drive signal and process the signal. The current position is calculated through the model, and the position signal is converted into a voltage value and fed back to the controller. Since the H-bridge signal includes H+ signal and H- signal, the controller needs to use two output terminals to output H+ signal and H- signal to the load resistor respectively.
[0038] In some instances, such as Figure 3 As shown, the load module 110 further includes: an inductor 112 having a first end and a second end, the first end of the inductor 112 being electrically connected to the input end of the hardware-in-the-loop test cabinet 200 and the first output end of the controller 300 respectively, and the second end of the inductor 112 being electrically connected to the first end of the load resistor 111.
[0039] In this example, the actuator is simulated by resistors and inductors. The resistance and inductance are selected according to the actual load characteristics, and there is no need to purchase the actual load (actual actuator). The controller is used to output PWM or H-bridge signals to drive the resistors and inductors. The HIL is used to collect the feedback signals of the resistors and inductors and process the signals. The current position of the valves simulated by the resistors and inductors (for example, the throttle, EGR valve, bypass valve, pressure regulating valve, etc. related to the engine controller) is calculated through the model, and the position signal is converted into a voltage value and fed back to the controller.
[0040] In some instances, such as Figure 3As shown, the load module 110 further includes: a blocking resistor 113 having a first end and a second end, the first end of the blocking resistor 113 being electrically connected to the first end of the load resistor 111, the input end of the hardware-in-the-loop test cabinet 200 and the first output end of the controller 300, and the second end of the blocking resistor 113 being electrically connected to the second end of the load resistor 111 and the second output end of the controller 300.
[0041] In this example, a stall resistor is added to simulate the fault state of a real valve. The stability of the output voltage and current and the circuit's ability to respond to the load can be tested through the load, and false alarms of open circuits and short circuits can be avoided.
[0042] In some instances, such as Figure 3 As shown, the load module 110 further includes: a switch module 114 having a first end and a second end, the first end of the switch module 114 being electrically connected to the first end of the load resistor 111, the input end of the hardware-in-the-loop test cabinet 200 and the first output end of the controller 300, respectively, and the second end of the switch module 114 being electrically connected to the first end of the blocking resistor 113.
[0043] In this example, by adding a switch module, the state of the simulated actuator can be adjusted arbitrarily. When the switch module is turned on, the fault state of the actuator is simulated, and when the switch module is turned off, the normal working state of the actuator is simulated.
[0044] In some instances, such as Figure 4 As shown, the hardware-in-the-loop test cabinet 200 further has a second output end, and the switch module 114 further has a control end. The control end of the switch module 114 is electrically connected to the second output end of the hardware-in-the-loop test cabinet 200 .
[0045] In this example, the hardware-in-the-loop test cabinet can control the on and off of the switch module through a control signal, thereby controlling the state of the actuator simulated by the load module.
[0046] In some embodiments, the switch module is a mechanical switch or a transistor.
[0047] In this example, when the switch module is a mechanical switch, the first end of the switch module and the control end are one end, that is, the first end of the switch module is electrically connected to the hardware-in-the-loop test cabinet for receiving the control signal of the hardware-in-the-loop test cabinet, and the second end of the switch module is grounded. When the switch module is a transistor, the switch module has three ends, namely the first end, the second end and the control end.
[0048] In some instances, such as Figure 5As shown, the hardware-in-the-loop test cabinet 200 also includes a real-time simulation chip 220, which has an input pin and a first output pin. The input pin of the real-time simulation chip 220 is electrically connected to the output end of the load box, and the first output pin of the real-time simulation chip 220 is electrically connected to the input end of the controller 300.
[0049] In this example, the real-time simulation chip is used to simulate the test results of the real actuator according to the feedback signal output by the load box. When the real actuator is used for testing, the drive motor generates a driving torque and transmits it to the valve plate. During the movement of the valve plate, the friction torque, the reset spring torque and the fluid disturbance resistance need to be overcome. Among them, according to the above principles, that is, the motor driving torque is related to the controller driving duty cycle, the friction torque is related to the speed direction and angular velocity, the spring nonlinear torque is related to the current position of the valve plate, and the disturbance torque is related to the fluid flow through the load. The real-time simulation chip can calculate the load position according to the model calculation and convert the position signal into a voltage signal to feed back to the controller. When it is necessary to simulate a fault, the HIL outputs a driving signal to control the conduction of the parallel circuit, and according to the needs, the real-time simulation chip adjusts the friction torque size according to the model to simulate jamming, stalling and other faults.
[0050] From the above description, it can be seen that the above embodiments of the present application achieve the following technical effects:
[0051] The technical solution of the present application is the above-mentioned load simulation test device, including: a load box, which is used to simulate real engine components; a hardware-in-the-loop test cabinet, the input end of the hardware-in-the-loop test cabinet is electrically connected to the output end of the load box, the hardware-in-the-loop test cabinet is used to receive the feedback signal of the load box to test the load box, and calculate and process the feedback signal to obtain a voltage signal; a controller, the input end of the controller is electrically connected to the first output end of the hardware-in-the-loop test cabinet and receives the voltage signal sent by the hardware-in-the-loop test cabinet, the first output end of the controller is electrically connected to the first input end of the load box, the second output end of the controller is electrically connected to the second input end of the load box, and the controller is used to send a drive signal to the load box to drive the load box. The device simulates the load through the load box, replaces the real actuator, can simulate the real opening position, switch and other states of the valve, realizes the closed loop of the controller and the hardware-in-the-loop test, reduces the development cost, shortens the development cycle, not only solves the problem that nonlinear loads are difficult to simulate and HIL cannot be closed without real loads, but also solves the problem that the existing actuators are expensive and difficult to simulate with real actuators in HIL tests.
[0052] The above embodiment uses inductance and resistance to simulate the real actuator, and can simulate various linear and nonlinear loads to replace the real load, without the need to purchase, which greatly saves costs, and can also conveniently and flexibly simulate faults such as jamming and stalling. By using simple resistors and inductors to simulate loads, the real actuator can be replaced, which solves the problem that nonlinear loads are difficult to simulate and HIL cannot be closed without real loads, and can achieve closed loops between controllers and HIL, shortening the development cycle.
[0053] The above description is only the preferred embodiment of the present application and is not intended to limit the present application. For those skilled in the art, the present application may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.
Claims
1. A load simulation test device, characterized in that: include: A load box having a first input terminal, a second input terminal and an output terminal, wherein the load box is used to simulate real engine components; A hardware-in-the-loop test cabinet, having an input end and a first output end, wherein the input end of the hardware-in-the-loop test cabinet is electrically connected to the output end of the load box, and the hardware-in-the-loop test cabinet is used to receive a feedback signal from the load box to test the load box, and to calculate and process the feedback signal to obtain a voltage signal; A controller having an input end, a first output end and a second output end, wherein the input end of the controller is electrically connected to the first output end of the hardware-in-the-loop test cabinet and receives the voltage signal emitted by the hardware-in-the-loop test cabinet, the first output end of the controller is electrically connected to the first input end of the load box, and the second output end of the controller is electrically connected to the second input end of the load box, and the controller is used to send a driving signal to the load box to drive the load box.
2. The load simulation test device according to claim 1, characterized in that: The load box also includes: At least one load module has a first input end, a second input end and an output end, the first input end of the load module is electrically connected to the first output end of the controller, the second input end of the load module is electrically connected to the second output end of the controller, and the output end of the load module is electrically connected to the input end of the hardware-in-the-loop test cabinet.
3. The load simulation test device according to claim 2, characterized in that: In the case where there are multiple load modules, the load modules are not connected to each other, the hardware-in-the-loop test cabinet has multiple input terminals, the controller has multiple first output terminals and multiple second output terminals, the number of input terminals of the hardware-in-the-loop test cabinet, the number of first output terminals of the controller and the number of second output terminals of the controller are the same, a group of corresponding first output terminals of the controller and second output terminals of the controller are used to send the drive signal to a corresponding load module, and the input terminal of the hardware-in-the-loop test cabinet is used to receive the feedback signal of the corresponding load module.
4. The load simulation test device according to claim 2, characterized in that: The load module comprises: A load resistor has a first end and a second end, wherein the first end of the load resistor is electrically connected to the input end of the hardware-in-the-loop test cabinet and the first output end of the controller respectively, and the second end of the load resistor is electrically connected to the second output end of the controller.
5. The load simulation test device according to claim 4, characterized in that: The load module also includes: The inductor has a first end and a second end, wherein the first end of the inductor is electrically connected to the input end of the hardware-in-the-loop test cabinet and the first output end of the controller respectively, and the second end of the inductor is electrically connected to the first end of the load resistor.
6. The load simulation test device according to claim 4, characterized in that: The load module also includes: A blocking resistor has a first end and a second end, wherein the first end of the blocking resistor is electrically connected to the first end of the load resistor, the input end of the hardware-in-the-loop test cabinet, and the first output end of the controller, and the second end of the blocking resistor is electrically connected to the second end of the load resistor and the second output end of the controller.
7. The load simulation test device according to claim 6, characterized in that: The load module also includes: The switch module has a first end and a second end, the first end of the switch module is electrically connected to the first end of the load resistor, the input end of the hardware-in-the-loop test cabinet and the first output end of the controller respectively, and the second end of the switch module is electrically connected to the first end of the blocking resistor.
8. The load simulation test device according to claim 7, characterized in that: The hardware-in-the-loop test cabinet further has a second output end, and the switch module further has a control end, and the control end of the switch module is electrically connected to the second output end of the hardware-in-the-loop test cabinet.
9. The load simulation test device according to claim 7, characterized in that: The switch module is a mechanical switch or a transistor.
10. The load simulation test device according to claim 1, characterized in that: The hardware-in-the-loop test cabinet also includes a real-time simulation chip, which has an input pin and a first output pin. The input pin of the real-time simulation chip is electrically connected to the output end of the load box, and the first output pin of the real-time simulation chip is electrically connected to the input end of the controller.