With the development and progress of the automobile industry, people have put forward higher requirements on the power, economy, safety and emissions of automobiles. The traditional mechanical control system is far from meeting these needs. The electronic control system has gradually replaced the mechanical control system with its high precision, high speed, flexible control, stability and reliability. It is the development trend of the vehicle control system.
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Due to the increasingly strict requirements on control performance, the requirements of the electronic control system of the automobile are getting higher and higher. The development and design of the controller generally goes through the steps shown in Figure 1, that is, a V-shaped process from the upper layer to the bottom layer, and then from the bottom layer to the upper layer. The first is the upper layer function design of the controller, which determines the functions that the controller will implement in detail; then generates the target program code; finally, the underlying software and hardware implementation of the controller.
Hardware-in-the-loop real-time simulation testing is also required from the controller implementation to the real vehicle test. This is because in the development process of the vehicle controller, the virtual vehicle controller environment is used to build a virtual vehicle site environment on the simulation test platform. The hardware-in-the-loop simulation test of the controller not only greatly speeds up the development process of the hardware and software of the vehicle controller, but also has a high reliability. Because the simulation test platform can simulate the special driving state and dangerous state that are difficult to achieve in the actual vehicle test, the vehicle controller is fully tested. In the hardware simulation of the controller, the system is replaced by a mathematical model. The controller uses the physical object. The interface between the system model and the controller must be consistent with the actual. After the simulation is completed, the controller and the system are reached. "Vertical installation" or "vertical integration". After completing the hardware-in-the-loop simulation, the controller can enter the system integration and testing, and finally realize the functions and indicators of the initial design.
Based on Matlab/Simulink RTW and XPC Real-time Target real-time simulation platform, with the development of the underlying software of PCI data acquisition card and the hardware design of signal conditioning device, this paper systematically realizes the simulation test platform of fuel cell vehicle vehicle controller. The platform can be used to test the hardware characteristics of the vehicle controller, the underlying software platform and control algorithms.
Hardware-in-the-loop real-time simulation test platform design
The hardware-in-the-loop real-time simulation platform builds a virtual vehicle environment, and based on the virtual human-computer interaction driver model, people are introduced into the actual simulation test as an element of hardware in the ring. The specific structure is shown in Figure 2. Two virtual platforms based on industrial control computers are virtual vehicle platforms and virtual driver platforms. The virtual vehicle platform is based on the Matlab/Simulink xPC Target real-time simulation environment, which simulates the operation of a real fuel cell bus and provides the required virtual control object for testing the vehicle controller. The virtual driver platform is based on the Matlab/Simulink RTW Target real-time simulation environment. It is used to simulate the real fuel cell bus control mechanism and cooperate with the accelerator pedal to provide the virtual driving environment required for testing the vehicle controller. When two computer virtual platforms simulate the actual environment, the data acquisition card and the CAN communication card are connected to the configurable signal processing device, and the configurable signal processing device processes the signals to realize a real complex vehicle environment. Directly connected to the vehicle controller for simulation test. It is equipped with a real-time monitoring device based on CAN bus, which can monitor the simulation test in real time.
Hardware-in-the-loop real-time simulation test platform hardware design
Virtual platform hardware design
The hardware of the virtual platform needs to complete the conversion of the virtual signal generated by the computer model to the real signal, including digital input and output signals, analog input and output signals, and CAN communication signals. For example, the fuel cell engine start switch signal belongs to a digital signal, the motor speed signal belongs to an analog signal, and the controller control command is transmitted through the CAN bus network.
The digital signal and analog signal of the virtual platform are exchanged with the real world through the data acquisition card of the PCI interface. The various communication cards used generally have the underlying software driver of Matlab, which can be directly used for real-time simulation. For some data acquisition cards that do not support Matlab real-time simulation environment, you can use the S function in Matlab/Simulink environment to write, and call the dynamic link library in Matlab environment. The PCI1731, PCI1723, and PCI1720 boards used in this article are not compatible with the Matlab driver, so they are integrated using the S function. The entire virtual platform has 32 digital input interfaces, 32 digital output interfaces, 32 digital input/output multiplexing interfaces, 32 analog input interfaces and 20 analog output interfaces.
The CAN signal generated or received by the virtual platform is connected to the CAN communication card through the PCI bus, and the CAN communication card communicates with the controller to be tested through the CAN bus. The virtual platform supports CAN2.0A and CAN2.0B extended protocols, and can output 2 independent CAN signals at the same time.
Signal Conditioner Hardware Design
Because the signals on the fuel cell passenger car are more complicated, the digital signals have different driving levels and driving modes such as 24V, 12V and 5V. The analog signals also have different voltage ranges and different driving power requirements. The signal output from the virtual platform through the data acquisition card is relatively simple. Therefore, after the signal conditioner is used to condition the signal, the real control interface on the fuel cell bus can be completely reproduced, and the simulation test is directly connected with the vehicle controller.
As shown in FIG. 2, the digital analog signal generated or received by the virtual platform is connected to the data acquisition card through the PCI bus. The data acquisition card and the configurable signal conditioner exchange data through a dedicated data line, and after the necessary amplification, level conversion, and logic conversion of the signal by the configurable signal conditioner, the output signal completely conforms to the actual vehicle. The signal specification is connected to the vehicle controller to be tested using a standard interface, thereby achieving a seamless connection to the vehicle controller. Different signal specifications for various vehicles can be achieved by adjusting the configuration of the configurable signal conditioner. The signal conditioner is designed for flexible mother board, the motherboard completes the task of universal signal connection power supply, and the daughter board completes the specific configurable signal processing function. The motherboard and the daughter board work together, and the daughter board circuit can be replaced at any time according to the needs of the user to meet the needs of different simulation tests.
Hardware-in-the-loop real-time simulation test platform software design
Virtual vehicle platform software design
The virtual vehicle platform builds a fuel cell vehicle simulation model based on the Matlab/Simulink platform, which includes a fuel cell engine, a DC-DC converter, a battery, an asynchronous drive motor, and a vehicle load. On the one hand, the model components of the system need to consider the accuracy of the model, on the other hand, they must meet the requirements of real-time. The entire model runs on the Matlab/Simulink xPC Target real-time simulation environment. The vehicle simulation model communicates with the driver and the vehicle controller through the PCI data acquisition card and the PCI CAN card.
Virtual driver platform software design
The virtual driver platform implements a virtual driving environment that can be operated by the driver. In addition to the driving acceleration signal input by the test personnel through the pedal, the rest of the vehicle start and stop switch, fuel cell switch, motor tachometer, speedometer, water temperature alarm and other control switches and instruments are implemented by the virtual driver platform. The whole model is based on Matlab/Simulink RTW Target real-time simulation environment, and the instrument display and control switch input are realized by Matlab Gauges toolbox. Gauges is a meter development tool for displaying monitoring data provided by Matlab in Simulink. The Gauges toolbox can be used to quickly develop a virtual vehicle instrumentation system in the Simulink model. The virtual driver simulation model also communicates with the driver and the vehicle controller through the PCI data acquisition card and the PCI CAN card.
Real-time performance analysis
Matlab/Simulink provides a good software environment for real-time simulation. The Real-Time Workshop code generation tool can compile simulation models to generate real-time C code and support a variety of real-time simulation target environments, including Matlab toolbox RTW Target, xPC Target, and third-party software such as dSPACE. This paper chose xPC Target and RTW Target to build virtual vehicle platform and virtual driver platform.
The vehicle virtual platform undertakes the task of reproducing the real fuel cell vehicle operation and is the core component of the entire test platform. Due to the complex structure of the fuel cell vehicle and the large number of control objects, in order to truly reproduce the operation of the whole vehicle, in addition to the accuracy requirements of the system components, the real-time requirements must be strictly met. The xPC Target real-time simulation environment adopted by the vehicle virtual platform adopts the structure of the target machine and the host machine. The real-time kernel generated by Matlab runs independently on the target machine through the floppy disk drive or USB flash memory, and directly calls the CPU resources. The simulation model is compiled by the host machine to generate real-time code and then downloaded to the target machine for running, which can realize strict system real-time simulation.
The RTW Target real-time kernel used in the virtual driver platform runs directly in the Matlab/Simulink environment, enabling real-time simulation of the system on the same PC. The disadvantage is that since the entire system runs under the Windows system, the real-time kernel cannot fully occupy the PC operating system resources, and the real-time performance is affected by other running programs. Since the driver simulation operation does not require real-time performance, the RTW Target real-time simulation environment can meet this requirement.
Real-time simulation signal definition
The signal definitions of the virtual vehicle platform and the virtual driver platform are shown in Table 1 and Table 2, which are completely consistent with the target fuel cell vehicle. The virtual vehicle platform defines the CAN network node protocol of each component controller of the fuel cell vehicle, as well as the vehicle controller brake signal input and the vehicle speed output. The virtual driver platform system signals include various driver command outputs and driver panel display information inputs, and define a data acquisition CAN node. In addition to the connection between the speed signal and the CAN network signal, all other signals of the virtual vehicle platform and the virtual driver platform interact with the vehicle controller.
experiment analysis
The simulation test platform can be used to perform real-time hardware-in-the-loop testing of the fuel cell vehicle controller. The vehicle controller is connected to the corresponding interface signal according to the real-time simulation signal definition through the signal conditioning device and the simulation test platform, and then the virtual vehicle platform and the virtual driver platform are respectively run, and can be used for testing.
The fuel cell vehicle hardware-in-the-loop real-time simulation platform has been successfully applied to the development of the "10th Five-Year" fuel cell city bus electronic control unit. The electrical characteristics of the vehicle controller digital and analog signals, control logic and algorithms, and fault diagnosis functions can be checked before the vehicle is on the vehicle. With the rapid prototyping tool dSPACE, the rapid prototyping vehicle controller testing process can be fully realized, as shown in Figure 3.
Based on the test of the simulation test platform, except that the vehicle controller to be tested is the actual vehicle controller, all the test environments are obtained from the virtual reality environment of the simulation test platform, and from the perspective of the controller, it is completely consistent with the real environment of the vehicle. Therefore, the low-cost, convenient and rapid test of the vehicle controller is carried out, which not only improves the development efficiency of the vehicle controller, but also improves the necessary testing process before the vehicle controller is on the vehicle, and reduces the necessary test process. The risk and cost of the vehicle controller for real vehicle testing. The platform is versatile and can be tested differently according to needs. It is not limited to the development of vehicle controllers and has broad application prospects.
After the vehicle controller is repeatedly tested by the simulation platform, the actual vehicle test will be carried out, and the data of each component obtained from the test provides conditions for further accurate matching and calibration of the simulation model, so that the simulation platform is more realistic.
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