Virtual ECU Simulation for Vehicle HILS Accuracy
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Solution Overview
Problem
In vehicle control systems, evaluating the operations of multiple interconnected electronic control units (ECUs) via Hardware In the Loop Simulation (HILS) is challenging due to the difficulty in obtaining real ECUs during design or development phases, and creating plant models for HILS is time-consuming.
Innovation Solution
A simulation apparatus comprising a model process portion, a controller simulation portion, and a management portion that allows for the simulation of control operations by substituting virtual controllers for real ones, enabling efficient formation of larger-scale integrated plant models even without all real controllers being present.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If HILS is provided for each ECU to evaluate cooperative control operations, then simulation accuracy is improved, but device complexity and cost increase due to requiring multiple real ECUs and plant models
Solution Approach 1:
The patent creates virtual copies of ECUs (virtual ECU 50B, 50C) that replicate the functionality and control logic of real ECUs. These virtual copies are implemented as software modules that can be executed on standard computing hardware, eliminating the need to obtain and manage multiple physical real ECUs while maintaining simulation accuracy for evaluating cooperative control operations.
Solution Approach 2:
The patent introduces a simulation management unit that acts as an intermediary between the real ECU and virtual ECUs. This management unit coordinates the operations of multiple ECUs, manages data exchange, and synchronizes control loops, thereby reducing the overall system complexity by centralizing coordination functions rather than requiring direct complex interactions between multiple real ECUs.
2Measurement precision
If real ECUs are obtained for HILS simulation, then control operation accuracy is improved, but availability deteriorates because real ECUs are often in design or development phases and difficult to obtain
Solution Approach 1:
Instead of requiring physical real ECUs that may be unavailable during design phases, the patent creates virtual replicas of these ECUs as software implementations. These virtual ECUs can be developed, modified, and executed independently of physical hardware constraints, ensuring continuous availability for simulation purposes while maintaining accurate representation of control operations.
Solution Approach 2:
The patent uses virtual ECU implementations that can be rapidly created, modified, and discarded as needed for different simulation scenarios. These software-based virtual ECUs are much easier to produce and update compared to physical real ECUs, allowing flexible adaptation to different development stages and simulation requirements without the constraints of hardware availability.
3Measurement precision
If plant models are created for all HILS systems, then simulation completeness is improved, but time consumption increases significantly
Solution Approach 1:
The patent divides the simulation system into modular components where each ECU (real or virtual) has its own dedicated plant model. This segmentation allows independent development and validation of individual plant models, which can then be assembled into complete simulation scenarios. The modular structure enables selective activation of only the necessary plant models for each specific simulation task, reducing overall time consumption while maintaining simulation completeness.
Solution Approach 2:
The patent implements plant models and virtual ECU configurations in advance during the development phase, allowing them to be reused across multiple simulation scenarios. By preparing these computational models beforehand, the system eliminates the need to create plant models from scratch for each simulation run, significantly reducing time consumption while ensuring simulation completeness is maintained through pre-validated models.
Data Source
AI summary
A simulation apparatus is composed of an integrated plant model process unit 1, virtual ECUs 50A to 50C that simulate other controllers, and a simulation management unit 2 that manages the execution of an input and output process to a real ECU 300, a process by the integrated plant model process unit 1, and a process by the virtual ECUs 50A to 50C, and so on, and the simulation management unit 2 causes the integrated plant model process unit 1, the virtual ECUs 50A to 50C, and so on to execute the processes required for the operation of the real ECU 300 during a given period on the basis of the operation of the real ECU 300.