Research On Hardware Testing System Based On LabCar Hardware

With the restriction of vehicle emission regulation and higher requirement for vehicle dynamic quality、economical efficiency、safety and comfort property, these trends promote the development of engine electronic control technology. ECU is an important component of engine electronic control system, and also is control hub of vehicle. ECU collects signals of every sensor, and ECU corrects important engine parameters by analyzing characteristics of signals. In this way, it makes engine work at the best condition. Because of the complexity and variety of engine working condition, requirements for ECU are increasing. Under the pressure of competition, development and testing cycle of ECU has to be cut down to reduce cost. If traditional development and testing process is applied, the cycle will be influenced and much working condition and ambient testing will not be conducted. Hardware-in-the-Loop testing technology not only can remedy the defects of traditional development and testing method, but also reduce the risks created by limitation testing and fault testing.LabCar is an ECU Hardware-in-the-Loop simulation testing system developed by Germany ETAS. LabCar is a virtual laboratory vehicle. It can receive control signals which are given out by ECU, and response rapidly based on ECU signals and feedback current operation. The defects of ECU software and hardware will be found as early as possible by LabCar system. What’ more, it replaced bench testing and real vehicle testing, and help reduce ECU development cost, improve development efficiency and cut down development cycle.Under research of engine electronic control technology, the Hardware-in-the-Loop test technology and the main form have been analyzed and summarized, and the ECU Hardware in-the-Loop test system had put forward based on LabCar. On the feature of LabCar, the design of Hardware-in-the-Loop test system module has been performed. The Hardware-in-the-Loop test platform has been structured by using the LabCar proprietary software and hardware, aiming to research the ECU function module testing. The LabCar model (DEVM) composition and function module has been studied, and with loading the LabCar operating software model, the accuracy of offline verification model has been proved.The selection and configuration of the power supply board, the choice of the board signals channel, the choice of the means of signals measurement, signals units conversion, the definition of crankshaft and camshaft angle, the conversion between physical signals and voltage signals in Hardware-in-the-Loop system which was set up based on LabCar have been studied in depth. LabCar I/O module(pressure sensor module、temperature sensor module、crankshaft and camshaft sensor module)have been debugged. Finally, under the environment of LabCar-EE, the DEVM model has been simulated, for the simulation of engine idle speed, the simulation of engine speed change, the simulation of speed up, the simulation of the curve of rail pressure, the simulation of the engine performance curve and the simulation results have been analyzed. By comparing and studying the results of simulation, it was proved that the Hardware-in-the-Loop system based on LabCar is feasible and can achieve the expected function.