Research And Development Of Hardware-In-the-Loop Test Bench For Engine ECU Based On XPC Target

Engine electronic control technology is one of the key technologies in engine development. By adopting advanced electronic control methods, the engine electronic control unit (ECU) could achieve optimal control of ignition, injection, air-fuel ratio and exhaust emission, which can keep the engine working in excellent conditions to attain the goal of performance improvement, safety promotion, energy conservation and emission reduction. However, the development of a mature engine ECU, as a rule, requires a great deal of experimental data from massive bench tests under various working conditions. Besides, later in the development, in order to ensure the safety and reliability of the ECU, tests under different conditions are needed to continuously improve and perfect the engine performance.Hardware-in-the-loop (HIL) test platform provides ideal closed-loop environment for the ECU control algorithms and functions development, and garantees the conversion from research achievements into products. HIL test platform can help develop the ECU control function rapidly, eliminate possible failure in advance and improve the performance of the designed products.With an understanding of the principles of the engine ECU and its applications in HIL test system, a preliminary plan of engine ECU HIL test platform design based on xPC Target was proposed. In the xPC Target environment, board driver modules, sensor signal interfaces and actuator signal mesurement interfaces were realized and validated. Geely MR479Q gasoline engine is the engine model prototype and the self-developed engine ECU is the to-be-tested object. Based on bench experiment data, in the enDYNA software environment, engine simulation model was configured and preprocessed to match the MR479Q engine. Then the offline simulation was done to validate the performance of model pricision and real-time. Finally, unit test, function test and system integration test were done to validate the precision and availability of HIL test platform. The results show that the HIL test platform can meet the general needs of engine ECU development and testing, and has a certain practicality.