Research And Development Of The Hardware In The Loop Simulation Platform For The Range-extender’s ECU Of Electric Vehicle

Under the background of increasingly nervous energy and increasinglyserious environmental pollution, the Extended-range-electric Vehicle (EREV), whichis a special hybrid electric vehicle, has gotten more and more attention by people forits unique advantages. Now, the Range Extender device (RE) has become the focusof the research on new energy vehicles, as the indispensable component of the EREV.For shortening the development time of RE’s ECU, reducing the cost of development,this paper do a research on the hardware-in-the-loop simulation (HILS) system forthe RE’s ECU.In this paper, the sufficient research on the current situation of the developmentthe EREV and the advantages or disadvantages of the HILS testing scheme weredone. Based on the work principle of the RE, a preliminary plan of the HILsimulation platform was proposed to meet the design requirement to RE’s ECU byusing the real-time simulation structure of MATLAB/xPC Target, The HILS systemincluding basic bench, signal interface system, load device and monitoring software.The developing work of each subsystem as following.The main work of the development of basic bench includes the following: todeveloping the driver module of the ADLINK PCI-6216V, PCI-7200, and PCI-7841under the xPC Target environment; to developing the RE’s and the typical sensors’real time model by using the Simulink and Stateflow. The signal interface system’sdeveloping work includes the following: to planning and configuring the PCI cards’ports of the basic bench; to regulating the input/output signals of the basic bench torealize the match of electrical characteristics between the basic bench and real ECUs.The work of developing load device is that, to simulating real load devices of theRE’s ECU by designing the hardware circuit, which make the functional test orperformance test be true. And then, the monitoring system was developed by using C#language, based on the xPC Target API for.NET Framework. This monitoringsystem is used to control the target-program, acquire the signal, and regulate theparameters in real-time. Finally, the HIL simulation platform was tested and verified.The test results are proving that the bench is useful in the development process ofECU, which make the development of the ECU of RE more easier and faster.