Research Of Hardware-In-The-Loop Simulation System (HILSS) Of Powertrain

With the development of automotive electronic technology, the application of powertrain is wider and wider. With the increasingly strict emission control regulations and severe energy crisis, the functions of the electronic control unit (ECU) need to be enhanced greatly and ECU is becoming more and more complex. In addition, with the increasingly severity of the market competition, the development cycle of ECU must be shortened. There must be an advanced development platform for the ECU development because the traditional ECU development method is time-consuming, costly, dangerous, and exists many uncertain factors. ECU hardware-in-loop simulation system (ECU HILSS) can debug the hardware and software of ECU easily. It can adjust software, optimize control arithmetic, do limit test and simulate fault condition. Such a system is introduced in this paper. This system is developed base on the ECU developed by ourselves.The traditional HILSS can only be applied in special system. Accodiing to the diverse papers and the idea of CONTROL BOX from BOSCH, a new HILSS development scheme is adopted in this paper based on the research work done by native and abroad researcher. This scheme intergtrates the function of HIL systems which were used for diversal powertrains and in the same time, this system uses the PC computer to run the real-time diesel engine model. The simulation ECU is developed with the 32-bit MCU of NEC and it provide the target ECU with the acceptable signals. The communication between PC and simulation ECU is completed by CAN BUS (Controller Area Network). The following jobs have been finished in this paper:1. The MCU of the simulation ECU is the 32-bit MCU V850E/GP1 of NEC. By using its module properly and designing effective peripheral circuits, the functions of the simulation ECU are realized. In the same time, this hardware can be used in different powertrain systems. The functions of the simulation ECU include sending cam shaft signal, crank shaft signal, and the simulative sensor signals to the target ECU, and measuring the driving signal of the target ECU.2. The program of the V850E/GP1 is programmed with assemble language and C language. There are 3 threads in the PC: the monitor-control interface thread, the real-time model thread and the communication thread. The monitor-control interface which realizes the functions of data display, parameter setting, operating condition adjusting and data storaging is developed by Labview. The real-time model thread and the communication thread are programmed by C++ and run in the background.3. The real-time model is the key of the HILSS, and it determines the feasibility of the whole system. The requirement on the real-time model is its accuracy and real-time processing ability. In this paper, the diesel engine model is simulated by MATLAB/SIMULINK. The key to realize the real-time ability of the model is that the software in PC is programmed with multi-thread technology. The SIMULINK model is converted to C++ code by hand, and the high precision time functions are used to ensure the real-time processing ability which means that the processing time of every cycle of the model thread is equal to the cycle time of the real engine.4. The CAN design is divided into two parts, the FCAN module of V850E/GP1 and USBCAN. The FCAN module develops by assemble language and the USBCAN develops by calling the interface of the driver. The communication is stable, and has high ability in anti-interference.