Physical Contactor Integration for Accurate HIL Feedback Validation
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Solution Overview
Problem
Existing HIL testing of contactors in battery management systems (BMS) relies on virtual models, which can produce false feedback signals and fail to simulate all real-world scenarios, leading to undetectable faults and erroneous readings.
Innovation Solution
Integrate a physical contactor with the HIL test bench to provide actual feedback signals, allowing the ECU to monitor and evaluate the feedback response accurately, detecting faults and ensuring reliable contactor operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a virtually modeled contactor is used in HIL testing, then the testing process is simplified and automated, but the feedback signals may be inaccurate and faults may remain undetectable
Solution Approach 1:
The patent merges the virtual HIL test environment with a physical contactor integrated into the test bench. The physical contactor is electrically connected to the HIL test bench controller and the ECU under test, creating a hybrid system that combines the automation benefits of virtual testing with the accuracy of physical feedback signals. This integration allows the ECU to receive authentic contactor feedback while maintaining automated test execution.
2Loss of time
If a virtually modeled contactor is used, then test setup is simpler and faster, but real-world scenarios cannot be fully simulated
Solution Approach 1:
The patent segments the testing system into distinct functional components: the virtual HIL test environment for automation and scenario definition, and the physical contactor for authentic feedback signal generation. This segmentation allows each component to excel at its specific function while working together to provide both rapid test setup and realistic scenario simulation.
3Device complexity
If contactor feedback is not validated with a physical contactor, then the test system is simpler, but erroneous readings occur
Solution Approach 1:
The patent implements a feedback validation mechanism where the physical contactor's actual feedback signals are fed back to the HIL test bench controller and the ECU under test. This feedback loop allows the system to compare expected feedback from the virtual model with actual feedback from the physical contactor, ensuring signal accuracy and reliability while maintaining system functionality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The integration of a physical contactor in the HIL test bench provides accurate feedback signals, reducing erroneous readings and enabling reliable testing and validation of contactor performance and ECU operation.
Implementation Method 1
A contactor has an electromagnetic circuit that operates to move a movable contact
Implementation Method 2
A contactor has an electromagnetic circuit that operates to move a movable contact
Data Source
AI summary
A test system includes a hardware-in-the-loop (HIL) test bench comprising a test controller configured to generate a test signal corresponding to a contactor command; a system controller configured to receive the test signal, generate a control signal based on the test signal, monitor a feedback path for a feedback response, evaluate the feedback response relative to the test signal, and detect a fault based on a mismatch between the test signal and the feedback response; and a contactor comprising a pair of fixed contacts, a main coil configured to receive an activation current based on the control signal, and a movable contact configured to, based on the main coil being energized by the activation current, make contact with the pair of fixed contacts to generate a closed feedback signal as the feedback response.