Development Of HIL Test Bench For Pneumatic ABS And Vehicle Attitude Warning Device

Today, Hardware-in-the-Loop (HIL) Simulation has been widely used and is becomingan irreplaceable part of vehicle electronic controller development. HIL is a kind ofsemi-physical simulation technology that allows engineers to place the critical parts of thephysical vehicle in an virtual environment, link them with full vehicle dynamics models andtest their functionality and reliability. It lets engineers evaluate the ECU performance beforea physical vehicle is available for testing, and provides an opportunity to reduce costs,improve quality,and shorten time to market.Compared to the developed countries, the research and development of vehicle chassiscontrol system is relatively backward in China. Mature products for large commercialvehicles are more lacking. And with the development of road transport, highway trafficsafety situation has become even worse. Therefore, developing HIL systems for evaluatingproduct-level ECUs is helpful in accelerating the transform of theoretical research intomature product, prompting high equipment rate of chassis electronic control products andenhancing the active safety of commercial vehicles in China.In this paper, a HIL simulation test bench has been developed for the testing of thepneumatic ABS ECU and a vehicle rollover/sideslip warning device.The ECU is WABCOABS-E4S/4M controller which is widely equipped on native commercial vehicles, and thewarning device is developed by a native research unit.Based on the research objectives mentioned above, Chapter II is starting from the studyof I/O signal characteristics and working principle of the ECU.And then the design schemeof the HIL test bench is determined, which includes the selection of real-time simulationenvironment and vehicle dynamics software, the configuration of hardware and softwaresignal interface and the structure of a small driving simulator.Chapter III firstly describes the hardware overall composition of the HIL test bench。And then the vehicle control mechanism on the driving simulator, the steering feel feedbackmechanism, the signal I/O boards and real time computers are respectively introduced.Chapter IV describes several important issues in the program designing of the HIL testbench, which include the connection between the vehicle model and the real-time system,the computation of desired rack force, the control strategy in the steering feel feedbacksystem and the ABS solenoid valve modeling. In Chapter V the connection between the target ECU and the HIL test bench isrealized.The wiring and signal definition of each ECU and the acquisition of the ECUcontrol signal is described in detail.In Chapter VI Several HIL simulations of different virtual test conditions are done onthe HIL test bench with the pneumatic ABS ECU and the vehicle rollover/sideslip warningdevice in the simulation loop. The simulation results are analyzed.The final Chapter is the summary and outlook of the whole paper. It summarizes thework completed in each chapter, points out the defects on current HIL test bench, and alsogives a general outlook of the future work.