Design And Implementation Of Hardware-in-the-loop Testing System For The Vehicle Engine ECU

The engine ECU (Electronic Control Unit) is the key component of vehicleelectronic control system. According to the signals of the sensors and its procedures orthe engine parameters, the ECU can provide the precise estimation, the comprehensiveanalysis of engine operating state and control effect, then obtain the best running statecontrol performance. Because of the complexity of ECU functions and internalstructures, it is very important to carry on the overall tests, especially the tests under theextreme conditions or malfunction tests. According to the traditional real vehicle test orthe bench test, a large number of experiments are needed. Then the testing period mustbe extended. And some special conditions are very difficult to obtain or need a veryhigh cost when testing the practical control object. So, a hardware-in-the-loopsimulation testing technology of engine ECU is studied in this thesis. It can overcomethe disadvantages of the preceding methods and reduce the design risk while there is nofully grasping of control effect at the same time.Firstly, the correlative background knowledge of engine electronic controltechnology and the hardware in the loop simulation technology are introduced, and thenecessary to set up the hardware in the loop testing system is put forward in this thesis.Based on the analysis and comparison of the present practical domestic and overseassolutions, the dSPACE project, which has a good expansibility and universality, isselected as the system structure. Then components are designed according to thedSPACE system structure. The DS1006processor board and DS2211I/O board areselected to build the system’s hardware platform; models of the engine electroniccontrol is setup through the MATLAB/Simulink real-time kernel. Off-line simulationverified the accuracy of the models preliminarily. From the dSPACE system real-timeinterface library, the APU module of DS2211board is selected to realize the safetyseamless real-time connection and automatic code generation of the models. And themonitoring interface is established to real-time data acquirement, display curve and datasaving by the ControlDesk.Finally, the debugging experiments of established ECU hardware in the looptesting system are done to test the steady state performance of the engine electroniccontrol system models. And the output characteristic curves of ECU injection pulsewidth and ignition advance angle versus signals of the condition sensors are obtained. The maps of injection pulse width and ignition advance angle are also processed indifferent throttle opening degree and speed. The experimental results show that thehardware in the loop testing system of the ECU of vehicle engine designed in this thesisis reasonable and feasible, and it can reach the scheduled function.