CN111007840A - Whole vehicle controller hardware-in-loop test platform and method - Google Patents
Whole vehicle controller hardware-in-loop test platform and method Download PDFInfo
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- G05B23/00—Testing or monitoring of control systems or parts thereof
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- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0208—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the configuration of the monitoring system
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Abstract
The invention discloses a hardware-in-loop test platform for a vehicle control unit, which comprises the vehicle control unit to be tested, a test cabinet and an upper computer, wherein the test cabinet comprises a fault simulation board and a VCU junction box of the vehicle control unit, the vehicle control unit to be tested is arranged in the VCU junction box, a vehicle simulation model is established in the upper computer, test software is operated, and a test instruction is sent to the fault simulation board, and the output end of the fault simulation board is connected with the IO port of the vehicle control unit and used for sending simulated fault state data to the vehicle control unit. The method has the advantage that the functional response of the control logic of the whole vehicle controller can be quickly tested.
Description
Technical Field
The invention relates to the field of vehicle test, in particular to a vehicle controller hardware-in-loop test platform and a vehicle controller hardware-in-loop test method.
Background
The problems of environmental pollution and shortage of petroleum energy caused by the traditional fuel oil vehicles are increasingly serious, and the electric vehicles are widely regarded as the key for solving the two problems. The power system of the whole pure electric vehicle mainly comprises a power battery, a power Battery Management System (BMS), a driving motor, a Motor Controller (MCU) and a whole vehicle controller. With the rapid development of new energy automobile technology, the requirements on the product performance and the reliability of the core components of the power system are higher and higher. In order to ensure the performance of these entire vehicle core components, especially the performance of the entire vehicle controller, which is the control core for coordinating and controlling the entire vehicle, it is necessary to perform various tests on the characteristics thereof.
At present, vehicle controllers on the market are various in types, but various performances of the vehicle controllers are difficult to evaluate, and the vehicle controllers are tested only by using real vehicles, so that the cost performance is low, the testing working conditions are limited, and the performances of the vehicle controllers under the limit driving working conditions can not be tested particularly. In addition, the control strategy of the vehicle control unit is continuously increased, and the traditional detection mode cannot meet the test precision and the requirement. If the model is in the ring and the software is in the ring, the test in the two stages cannot meet the precision and the requirement of the real vehicle test, a driver is required during the real vehicle test, a VCU engineer must follow the vehicle to test on site, the test time is easily influenced by weather, environment, roads and the like, the efficiency is low, and the cost is high. If a problem exists in the VCU during the real-vehicle test, the VCU needs to be reworked and repaired, so that the development period of the VCU is prolonged, and the development cost is increased.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a hardware-in-loop test platform and a test method for a vehicle control unit, which are used for realizing the rapid test of the functional response of the control logic of the vehicle control unit.
In order to achieve the purpose, the invention adopts the technical scheme that: the utility model provides a vehicle control unit hardware is at ring test platform, includes real-vehicle control unit, test rack, the host computer that awaits measuring, the test rack includes fault simulation board, vehicle control unit VCU junction box, and the vehicle control unit that awaits measuring sets up in the VCU junction box, establish whole car simulation model and operate test software in the host computer and send test instruction to the fault simulation board, the IO mouth of vehicle control unit is connected to the output of fault simulation board for send the fault state data of simulation to vehicle control unit.
The vehicle control unit is arranged in the VCU junction box and is connected with the cabinet mainly through a wiring harness, one end of the wiring harness is connected with the vehicle control unit through a connector, the other end of the wiring harness is connected with the cabinet through an EDAC connector, and the EDAC is a connector special for the cabinet.
The vehicle simulation model is built based on simulink and is used for simulating a model of a real vehicle, and the model comprises a power system, a transmission system, a chassis system, a driver model and a road working condition model.
The test cabinet also comprises a power supply management module, a low-voltage direct-current control power supply, a signal conditioning power supply and a real vehicle power supply simulation board, wherein the low-voltage direct-current control power supply and the signal conditioning power supply are respectively connected with the power supply management module and used for receiving the management control of the power supply management module; and the output end of the signal conditioning power supply is connected with the fault simulation board and the wiring layer and used for supplying power to the fault simulation board and the wiring layer.
The platform further comprises a real-time system, the real-time system comprises a real-time processor and a communication board card, the real-time processor is used for calculating models and the like, and the communication board card is used for achieving functions of real-time communication, DBC and XNET leading-in, analysis, enabling, triggering, timing receiving and sending and the like.
The fault simulation board is used for simulating fault signals including open circuit, broken circuit and other faults and monitoring voltage values of related lines.
The test software comprises Veristand, fault injection software and automatic test case writing software.
The test software comprises: completing engineering configuration, UI interface construction and the like through Veristand; the UI interface can realize manual testing, and the automated test case software can call Veristand engineering, so that automated testing is realized.
A test method of a hardware-in-loop test platform of a vehicle control unit comprises the following steps:
(1) performing Pin distribution according to an electric schematic diagram, Pin definition and the like of the whole vehicle controller, compiling a signal list, manufacturing a connecting wire harness, and connecting all parts according to a platform connection relation;
(2) and model development: an IO model in the vehicle simulation model is built according to the characteristics of each sensor, the actuator, the DBC file, the CAN matrix, the whole vehicle network topological graph and the like; building models of a power system, a transmission system, a chassis system and the like according to the overall structure parameters of the vehicle, the parameters of a motor/battery and the like; building various virtual controller models according to the whole vehicle function definition to simulate the real control function of the vehicle;
(3) and developing a test environment: configuring a hardware board card of a test cabinet, a DBC file and a corresponding file generated by model compiling in test software, and constructing a user interface which is operated and displayed in real time for monitoring the display of various variables and controlling the online modification and calibration of variable parameters in real time;
(4) compiling an automatic test case: according to the vehicle-finished function definition, the automatic test software is used for compiling test cases, the vehicle-finished controller is tested, and a test report is generated.
The invention has the advantages that: (1) providing a new testing means and method for the vehicle control unit of the pure electric vehicle;
(2) the cost performance is high, and the automobile fault simulation and the test of the VCU performance under the limit driving working condition can be realized;
(3) the VCU in the research and development stage can be quickly verified in control logic and functional response under the laboratory environment, and the development and debugging of the VCU are assisted;
(4) the test platform is easy to expand, a whole vehicle simulation model is built by using simulink, the follow-up continuity is improved, various control algorithms are added, the test platform is closer to a real vehicle state, more and more comprehensive tests can be completed in a hardware loop test stage, the real vehicle test working condition is effectively reduced, the development cost is reduced, and the development period is shortened.
Drawings
The contents of the expressions in the various figures of the present specification and the labels in the figures are briefly described as follows:
FIG. 1 is a block diagram of an overall test cabinet according to an embodiment of the invention;
FIG. 2 is a signal flow diagram of a system according to an embodiment of the present invention;
fig. 3 is a schematic diagram of a system according to an embodiment of the invention.
The reference numbers in the figures are respectively:
1-a power management module; 2-low voltage dc control power supply; 3-a real vehicle power supply simulation board; 4-a resistor simulation board; 5-a signal conditioning power supply; 6-mask; 7-a load box; 8-VCU junction box; 9-fault simulation board; 10-a wiring layer; 11-a communication board card; 12-a real-time processor; 13-analog input and output; 14-digital input output; 15-vehicle control unit; 16-real vehicle; 17-a test cabinet; 18-vehicle simulation model; 19-control algorithm.
Detailed Description
The following description of preferred embodiments of the invention will be made in further detail with reference to the accompanying drawings.
The utility model provides a vehicle control unit hardware is at ring test platform, includes real-vehicle control unit, test rack, the host computer that awaits measuring, and the test rack includes fault simulation board, vehicle control unit VCU junction box, and the vehicle control unit that awaits measuring sets up in the VCU junction box, and in establishing whole car simulation model and running test software and sending test instruction to the fault simulation board in the host computer, the IO mouth of vehicle control unit is connected to the output of fault simulation board for fault state data transmission to vehicle control unit with the simulation. The failure testing principle is that the vehicle controller is arranged in a testing cabinet, then a built vehicle model is operated by an upper computer (computer) to simulate the state of a real vehicle, testing software is operated on the computer to simulate the failure signal of the vehicle, then inputting the fault signals into a model, enabling the model to simulate faults according to test software, sending fault signals to a fault simulation board in a test cabinet by an upper computer in a software signal mode, sending the fault signals to a vehicle controller by the fault simulation board, monitoring response signals and control logic of the vehicle controller, finally feeding collected vehicle controller state signals back to a computer of the upper computer, analyzing and displaying the control logic, the response signals and the like of the vehicle controller by the computer, and then the interaction logic, the control logic and the response state of the vehicle controller are analyzed, so that the simulation fault test of the vehicle controller is realized. During testing, the control logics of other parts related to the vehicle controller are realized by using a simulink model except for the vehicle controller, and then a test instruction is sent to the vehicle controller through test software to verify whether the response logic and the signals of the vehicle controller are consistent as the previous function definition and whether the test result is consistent with the expected value, so that the comprehensive test and verification of the control strategy of the vehicle controller are realized. During testing, except the whole vehicle controller, other whole vehicle models are realized in a computer in a software simulation mode, then a fault signal is sent to a simulation board and then forwarded to the whole vehicle controller after testing is performed through testing software, then the logic state and the response signal of the whole vehicle controller are monitored, the control logic of the whole vehicle controller can be operated on the whole vehicle model to respond to the control signal of the whole vehicle controller, and therefore testing of the whole vehicle controller can be achieved. The platform is not only fault simulation, but also only has one function, and mainly verifies the correctness of the control logic strategy of the whole vehicle, and tests the control logic of the vehicle by testing whether the output signal is consistent with an expected value, such as gear switching, power-on and power-off processes and the like, so that a fault and logic test platform is formed and used for testing the whole vehicle controller.
As shown in fig. 1-3, a pure electric vehicle controller hardware-in-loop test platform includes: the test equipment cabinet comprises a real-time system, a power management module, a low-voltage direct-current control power supply, a fault simulation board, a real vehicle power simulation board, a resistor simulation board, a simulation input/output board and a digital input/output board, the whole vehicle simulation module comprises a vehicle simulation model, the test software comprises Veristand, fault injection software and automatic test case compiling software, and the computer is connected with the test equipment cabinet through a network cable;
the real-time system comprises a real-time processor 12 and a communication board card 11, wherein the real-time processor is used for calculating models and the like, and the communication board card is used for realizing functions of real-time communication, DBC, XNET import, analysis, enabling, triggering, timing transceiving and the like;
the power management module 1 is used for managing control of each power supply and mainly comprises an NI case power supply, a programmable power supply and a signal conditioning power supply;
the low-voltage direct-current control power supply 2 is used for controlling a direct-current power supply through the cabinet;
the fault simulation board 9 is used for simulating faults such as open circuit and open circuit of signals and monitoring voltage values of related lines;
the real vehicle power supply simulation board 3 is used for supplying power to the whole vehicle controller and simulating common power supplies on the vehicle, such as KL30, KL15 and the like;
the resistor simulation board 4 is used for simulating resistor channels with different resistance ranges;
the analog input/output board 13 and the digital input/output board 14 are used to configure analog input/output and digital input/output signals.
Furthermore, the test cabinet comprises a VCU junction box 8, the whole vehicle controller can be placed in the VCU junction box, and the VCU junction box is connected with the test cabinet through a wiring harness, so that semi-physical simulation test is realized.
Further, the vehicle simulation model 18 is a model for simulating a real vehicle built based on simulink, and mainly includes an IO model (power supply, hard line and CAN IO), a driver model, a road condition model, a virtual controller model (BMS/MCU/DCDC/OBC/vacuum pump, etc.), a vehicle power system, a transmission system, a chassis system, an electrical system, a power supply system, etc., and in combination with specific vehicle parameters, a more real and reliable simulation effect is achieved.
Further, the testing software is used for completing configuration of engineering, building of a UI interface and the like through Veristand. The UI interface can realize manual testing, and the automated test case software can call Veristand engineering, so that automated testing is realized.
Further, the test cabinet 17 further comprises a fault simulation board 9, and by combining fault injection software and automated test case software, the opening/closing of the relay can be controlled through direct operation on an upper computer interface, so that manual/automatic fault injection tests are realized, and some faults which are inconvenient or cannot be simulated on a real vehicle are simulated.
As shown in fig. 1, the testing cabinet includes: the system comprises a power management module, a low-voltage direct-current control power supply, a real vehicle power supply simulation board, a resistance simulation board, a signal conditioning power supply, a mask, a load box, a VCU (virtual circuit Unit) junction box, a fault simulation board, a junction layer, a communication board card, a real-time processor, analog input and output and digital input and output. The test cabinet is connected with a computer (an upper computer) through a network cable, and the vehicle control unit is connected with an EDAC board card in the VCU junction box through a connector and a wiring harness.
As shown in fig. 2, first the power management module is used to control the NI chassis power, the programmable power and the signal conditioning power. And secondly, the positive pole of the low-voltage direct-current control power supply is connected with the real vehicle power supply simulation board, the negative pole of the low-voltage direct-current control power supply is directly connected with the whole vehicle controller, and the low-voltage direct-current power supply is controlled through the cabinet. The signal conditioning power supply can classify hardware resources according to signal types, and can also select and configure the ground wires through jumper wires thereof to perform centralized management on the ground wires, thereby facilitating wiring and inhibiting interference; in addition, the signal conditioning power supply can amplify, filter, protect and the like certain signals, and the signal flow of the signal conditioning power supply flows to the fault simulation board and the wiring layer. The real-time processor is connected with the wiring layer through a flat cable, and a model can be calculated. The real-time system can realize functions of real-time communication, DBC and XNET import, analysis, enabling, triggering, timing transceiving and the like; the fault simulation board is used independently in a wiring mode, each board card comprises 10 channels, and a computer is connected with a fault injection port of the test cabinet through an RS232 serial port line, so that fault simulation is performed through software.
As shown in fig. 3, the test adopts the vehicle-mounted vehicle controller, the control algorithm (software) is written in, the vehicle controller is connected with the EDAC plug-in the VCU junction box through the wiring harness and the plug-in, the computer is connected with the test cabinet through the network cable, and the vehicle simulation model is adjusted by combining the upper computer to control the operation of the whole system.
Specifically, the test method of the hardware-in-loop test platform of the pure electric vehicle controller comprises the following steps:
1. firstly, Pin allocation is carried out according to an electric principle diagram, Pin definition and the like of the whole vehicle controller, a signal list is compiled, and a connecting wire harness is manufactured; and then the components are connected together by adopting a wire harness or a plugboard and the like to form the test platform.
2. Secondly, model development: an IO model in the vehicle simulation model is built according to the characteristics of each sensor, the actuator, the DBC file, the CAN matrix, the whole vehicle network topological graph and the like; building models of a power system, a transmission system, a chassis system and the like according to the overall structure parameters of the vehicle, the parameters of a motor/battery and the like; building various virtual controller models according to the whole vehicle function definition to simulate the real control function of the vehicle; (all models were developed based on simulink)
3. Then, the test environment develops: configuring a hardware board card of a test cabinet, a DBC file and a corresponding file generated by model compiling in test software, and constructing a user interface which is operated and displayed in real time for monitoring the display of various variables and controlling the online modification and calibration of variable parameters in real time;
4. compiling an automatic test case: according to the vehicle-finished function definition, compiling a test case by using automatic test software, testing the vehicle-finished controller and generating a test report; and sending the fault information to a fault simulation board for fault simulation by adopting a test software automatic test mode, sending a fault signal to the vehicle control unit, monitoring the corresponding output of the vehicle control unit in real time, and sending the detected response output to a computer for statistical analysis to generate a test report.
5. And finally: and analyzing the test data and the test report, perfecting the strategy of the whole vehicle controller, adding a new test case and perfecting a test case library.
It is clear that the specific implementation of the invention is not restricted to the above-described embodiments, but that various insubstantial modifications of the inventive process concept and technical solutions are within the scope of protection of the invention.
Claims (9)
1. The utility model provides a vehicle control unit hardware is at ring test platform which characterized in that: the test cabinet comprises a fault simulation board and a VCU junction box of the whole vehicle controller, the whole vehicle controller to be tested is arranged in the VCU junction box, a whole vehicle simulation model is established in the upper computer, test software is operated, and a test instruction is sent to the fault simulation board, and the output end of the fault simulation board is connected with the IO port of the whole vehicle controller and used for sending simulated fault state data to the whole vehicle controller.
2. The vehicle control unit hardware-in-loop test platform of claim 1, wherein: and a vehicle control unit is arranged in the VCU junction box.
3. The vehicle control unit hardware-in-loop test platform of claim 1, wherein: the vehicle simulation model is built based on simulink and is used for simulating a model of a real vehicle, and the model comprises a power system, a transmission system, a chassis system, a driver model and a road working condition model.
4. The vehicle control unit hardware-in-loop test platform of claim 1, wherein: the test cabinet also comprises a power supply management module, a low-voltage direct-current control power supply, a signal conditioning power supply and a real vehicle power supply simulation board, wherein the low-voltage direct-current control power supply and the signal conditioning power supply are respectively connected with the power supply management module and used for receiving the management control of the power supply management module; and the output end of the signal conditioning power supply is connected with the fault simulation board and the wiring layer and used for supplying power to the fault simulation board and the wiring layer.
5. The vehicle control unit hardware-in-loop test platform of any one of claims 1 to 4, wherein: the platform further comprises a real-time system, the real-time system comprises a real-time processor and a communication board card, the real-time processor is used for calculating models and the like, and the communication board card is used for achieving functions of real-time communication, DBC and XNET leading-in, analysis, enabling, triggering, timing receiving and sending and the like.
6. The vehicle control unit hardware-in-loop test platform of any one of claims 1 to 4, wherein: the fault simulation board is used for simulating fault signals including open circuit, broken circuit and other faults and monitoring voltage values of related lines.
7. The vehicle control unit hardware-in-loop test platform of any one of claims 1 to 4, wherein: the test software comprises Veristand, fault injection software and automatic test case writing software.
8. The vehicle control unit hardware-in-loop test platform of any one of claims 1 to 4, wherein: the test software comprises: completing engineering configuration, UI interface construction and the like through Veristand; the UI interface can realize manual testing, and the automated test case software can call Veristand engineering, so that automated testing is realized.
9. The method for testing the hardware-in-the-loop test platform of the vehicle control unit according to any one of claims 1 to 8, wherein: the method comprises the following steps:
(1) performing Pin distribution according to an electric schematic diagram, Pin definition and the like of the whole vehicle controller, compiling a signal list, manufacturing a connecting wire harness, and connecting all parts according to a platform connection relation;
(2) and model development: an IO model in the vehicle simulation model is built according to the characteristics of each sensor, the actuator, the DBC file, the CAN matrix, the whole vehicle network topological graph and the like; building models of a power system, a transmission system, a chassis system and the like according to the overall structure parameters of the vehicle, the parameters of a motor/battery and the like; building various virtual controller models according to the whole vehicle function definition to simulate the real control function of the vehicle;
(3) and developing a test environment: configuring a hardware board card of a test cabinet, a DBC file and a corresponding file generated by model compiling in test software, and constructing a user interface which is operated and displayed in real time for monitoring the display of various variables and controlling the online modification and calibration of variable parameters in real time;
(4) compiling an automatic test case: according to the vehicle-finished function definition, the automatic test software is used for compiling test cases, the vehicle-finished controller is tested, and a test report is generated.
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