汽车动力总成电控单元硬件在环测试系统研究
摘要
以ECU为核心的汽车电子控制技术极大的提高了汽车的动力性、燃油经济性,降低了尾气排放量。ECU的复杂程度逐渐提高,控制逻辑也变得越来越复杂,而开发周期却要求越来越短。为了解决ECU控制功能的复杂化与快速开发之间的矛盾,ECU的开发过程采用了“V”模式开发流程。在ECU的“V”模式开发流程中,硬件在环仿真测试是整个开发流程的一个重要环节,它对缩短ECU的开发周期,提高ECU产品的质量和可靠性起着至关重要的作用。本文为了解决汽车动力总成ECU开发过程中在线测试的复杂和不便,针对汽车动力总成ECU的硬件在环仿真测试,开发了一套测试工具——汽车动力总成ECU硬件在环测试系统,适用于多种动力总成ECU在实验室环境中进行硬件在环仿真测试。
汽车动力总成ECU硬件在环测试系统是为ECU开发的调试与测试工具,它为ECU提供虚拟的硬件试验环境,生成各种汽车传感器仿真信号、为ECU的驱动信号提供各种模拟执行器、检测ECU的驱动信号是否正常工作,考核ECU软件控制策略是否满足使用要求,它为ECU在试验环境中的调试与测试提供基础。为此,本文对汽车动力总成ECU硬件在环测试系统进行深入、系统的研究,论文完成的主要研究工作如下:
1)详细分析了国内外汽车动力总成ECU硬件在环测试技术的发展现状。并对多种动力总成ECU的工作环境以及输入输出信号的特点做了综合分析,提出了ECU硬件在环测试系统总体设计方案。
2)根据ECU驱动点火线圈初级绕阻的特点及其测试需求,建立了点火线圈的电路模型,提出了只保留了点火线圈初级绕阻的简化电路模型。电路模型中增加了能量泄放回路,以保证其电流曲线与真实点火线圈一致。通过对点火线圈两个电路模型的仿真分析和对比,证明了点火线圈简化电路模型能够非常精确地模拟点火线圈初级绕阻的电流,并具有电路结构简单的特点,非常适用于硬件在环仿真系统中模拟执行器开发。
3)阐述了汽车常用传感器输出信号的建模方法,重点介绍了磁电式传感器、爆震传感器信号数学模型的建立。基于所建数学模型,提出了利用双通道直接数字频率合成技术生成曲轴转速传感器信号、凸轮轴位相传感器信号和爆震传感器信号的方法。阐明了通过用高端MCU与双通道DDS技术结合的方法实现复杂波形的途径。解决了在不增加硬件复杂程度的前提下三路复杂信号同时输出的问题。
4)设计开发出具有自主知识产权的汽车动力总成ECU硬件在环测试系统,通过对系统的检测试验证明所开发系统的有效性。利用该系统可实现对汽车动力总成ECU的室内台架离线性能检测和调校,克服了以往在ECU研发过程中需要利用汽车动力总成物理样机进行其ECU性能测试和调校带来的操作不便、试验成本高的不足。
5)以硬件在环测试系统的架构为基础,建立了多样品、不需要人工干预的ECU可靠性自动测试系统,可同时满足14台ECU样品的在线测试,通过CAN网络完成14套硬件模拟器与工控机的数据交换,并对每台ECU的各种测试数据和发生的故障进行自动记录,实现ECU可靠性测试试验的全程自动化。
Automotive electronic control technology based on ECU has greatly improved dynamic, fuel economy, and reduced exhaust gas emission of automobile. Nowadays, ECU’s structure and control technology becomes more and more complex, but the development cycle becomes more and more short. To solve the contradiction between complex requirements and rapid development, the development of ECU often adopts V-model. In the V-model development lifecycle, hardware-in-the-loop (HIL) testing plays an important part, which can shorten development cycle, improve reliability and quality of ECU. In this paper, to solve the difficulty of ECU testing, and for the HIL testing of automotive powertrain ECU, a testing tool is introduced, which is called hardware-in-the-loop testing System. It applies to HIL testing of different kinds of automotive powertrain ECU in laboratory environment.
HIL testing System is a testing and debugging tool for the development of ECU, which provides a virtual automobile environment in laboratory, generates all kinds of sensor signals of automobile, and provides various simulated actuators for ECU. Furthermore the testing system also can test whether the driving signals of ECU are normal and whether the software control strategy is correct. For this purpose, this paper presents a thorough research on the HIL testing for automotive powertrain ECU. The main contents are as follows:
1) Analyzes in detail the current situation of HIL testing at home and abroad. By analyzing input and output signals of many kinds of automotive powertrain ECUs, an overall project design is put forward.
2) In this paper, a circuit model is set up for ignition coil. ECU drives only primary winding of ignition coil, for which reason and considering the testing requirement of ECU, the simplified circuit model is set up. The simplified circuit model keeps primary winding only, and adds bleeder circuit which ensures the current curve of circuit model is in accordance with real ignition coil. Through the simulation analysis, proves the simplified circuit model can simulate the primary winding current of ignition coil exactly. The model has the characteristic of simple structure, so it fits to the development of simulated actuator.
3) Describes the model creation method of automobile sensor output signal, introduces emphatically the model creation method of camshaft position sensor, crankshaft position sensor and knock sensor output signals. Base on the model, two-channel direct digital synthesizer (DDS) method is put forward. By using this method, camshaft position sensor, crankshaft position sensor and knock sensor simulated signals can be generated. By using high-end MCU and two-channel DDS, realizes the generation of three complex signals at the same time and without aggravating the hardware cost.
4) Designs and develops HIL testing system for automotive powertrain ECU, which has independent intellectual property. Through verification testing, proves the validity of the system. This system realizes the in-line testing without test bench in laboratory environment, and solves the problems of difficulty and high cost of in-line testing.
5) Based on the structure of HIL testing system, A ECU reliability testing system is set up, which can realize the unmanned operation, multiply samples reliability testing of ECU. This system can test fourteen samples at the same time, and realize automation completely in testing, test data recording and test error recording.
汽车动力总成ECU硬件在环测试系统是为ECU开发的调试与测试工具,它为ECU提供虚拟的硬件试验环境,生成各种汽车传感器仿真信号、为ECU的驱动信号提供各种模拟执行器、检测ECU的驱动信号是否正常工作,考核ECU软件控制策略是否满足使用要求,它为ECU在试验环境中的调试与测试提供基础。为此,本文对汽车动力总成ECU硬件在环测试系统进行深入、系统的研究,论文完成的主要研究工作如下:
1)详细分析了国内外汽车动力总成ECU硬件在环测试技术的发展现状。并对多种动力总成ECU的工作环境以及输入输出信号的特点做了综合分析,提出了ECU硬件在环测试系统总体设计方案。
2)根据ECU驱动点火线圈初级绕阻的特点及其测试需求,建立了点火线圈的电路模型,提出了只保留了点火线圈初级绕阻的简化电路模型。电路模型中增加了能量泄放回路,以保证其电流曲线与真实点火线圈一致。通过对点火线圈两个电路模型的仿真分析和对比,证明了点火线圈简化电路模型能够非常精确地模拟点火线圈初级绕阻的电流,并具有电路结构简单的特点,非常适用于硬件在环仿真系统中模拟执行器开发。
3)阐述了汽车常用传感器输出信号的建模方法,重点介绍了磁电式传感器、爆震传感器信号数学模型的建立。基于所建数学模型,提出了利用双通道直接数字频率合成技术生成曲轴转速传感器信号、凸轮轴位相传感器信号和爆震传感器信号的方法。阐明了通过用高端MCU与双通道DDS技术结合的方法实现复杂波形的途径。解决了在不增加硬件复杂程度的前提下三路复杂信号同时输出的问题。
4)设计开发出具有自主知识产权的汽车动力总成ECU硬件在环测试系统,通过对系统的检测试验证明所开发系统的有效性。利用该系统可实现对汽车动力总成ECU的室内台架离线性能检测和调校,克服了以往在ECU研发过程中需要利用汽车动力总成物理样机进行其ECU性能测试和调校带来的操作不便、试验成本高的不足。
5)以硬件在环测试系统的架构为基础,建立了多样品、不需要人工干预的ECU可靠性自动测试系统,可同时满足14台ECU样品的在线测试,通过CAN网络完成14套硬件模拟器与工控机的数据交换,并对每台ECU的各种测试数据和发生的故障进行自动记录,实现ECU可靠性测试试验的全程自动化。
Automotive electronic control technology based on ECU has greatly improved dynamic, fuel economy, and reduced exhaust gas emission of automobile. Nowadays, ECU’s structure and control technology becomes more and more complex, but the development cycle becomes more and more short. To solve the contradiction between complex requirements and rapid development, the development of ECU often adopts V-model. In the V-model development lifecycle, hardware-in-the-loop (HIL) testing plays an important part, which can shorten development cycle, improve reliability and quality of ECU. In this paper, to solve the difficulty of ECU testing, and for the HIL testing of automotive powertrain ECU, a testing tool is introduced, which is called hardware-in-the-loop testing System. It applies to HIL testing of different kinds of automotive powertrain ECU in laboratory environment.
HIL testing System is a testing and debugging tool for the development of ECU, which provides a virtual automobile environment in laboratory, generates all kinds of sensor signals of automobile, and provides various simulated actuators for ECU. Furthermore the testing system also can test whether the driving signals of ECU are normal and whether the software control strategy is correct. For this purpose, this paper presents a thorough research on the HIL testing for automotive powertrain ECU. The main contents are as follows:
1) Analyzes in detail the current situation of HIL testing at home and abroad. By analyzing input and output signals of many kinds of automotive powertrain ECUs, an overall project design is put forward.
2) In this paper, a circuit model is set up for ignition coil. ECU drives only primary winding of ignition coil, for which reason and considering the testing requirement of ECU, the simplified circuit model is set up. The simplified circuit model keeps primary winding only, and adds bleeder circuit which ensures the current curve of circuit model is in accordance with real ignition coil. Through the simulation analysis, proves the simplified circuit model can simulate the primary winding current of ignition coil exactly. The model has the characteristic of simple structure, so it fits to the development of simulated actuator.
3) Describes the model creation method of automobile sensor output signal, introduces emphatically the model creation method of camshaft position sensor, crankshaft position sensor and knock sensor output signals. Base on the model, two-channel direct digital synthesizer (DDS) method is put forward. By using this method, camshaft position sensor, crankshaft position sensor and knock sensor simulated signals can be generated. By using high-end MCU and two-channel DDS, realizes the generation of three complex signals at the same time and without aggravating the hardware cost.
4) Designs and develops HIL testing system for automotive powertrain ECU, which has independent intellectual property. Through verification testing, proves the validity of the system. This system realizes the in-line testing without test bench in laboratory environment, and solves the problems of difficulty and high cost of in-line testing.
5) Based on the structure of HIL testing system, A ECU reliability testing system is set up, which can realize the unmanned operation, multiply samples reliability testing of ECU. This system can test fourteen samples at the same time, and realize automation completely in testing, test data recording and test error recording.
引文
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