Research And Implementation Of Automation HIL Simulation And Test Platform For Automotive Engine ECU

In a few decades time, the car has undergone dramatic change. the form of car developedto be a high degree complex intergration of the mechanical and electronic from a simplearchitecturn of an engine and some wheels. At the same time, the the engine as the corecomponent of the automotive powertrain systems, but also occurred significantly change.Which the most important is the engine control system, it evolved from the original simplemechanical control system to the powerful electronic control system. Followed by this, thenumber and complexity of automotive electronic control unit increased exponentially, and it ismore demanding for the hardware and software test engineers. The first reason, as most of theconventional methods, we can complete limit theoretical validation and single test only, and itis often costly and invalid, because we are different to find bugs through early theoryauthentication and single test, and if we find a bug in the final vehicle test, we must re-designthe hardware and software of engine ECU, it will cost a lot of time and resources; Second,pure manual testing workload is very heavy, and so many repetitive work is too boring tocomplete for the testing engineers. So we need to find a way that test the hardware andsoftware thoroughly in the early stage of the engine ECU R&D cycle and try to identifyproblems early.Automatic hardware in the loop simulation and test platform is designed for this pupose,the simulation and test platform can simulate the operating conditions of the engine to bedeveloped in the early stage of the R&D cycle. It can provide a integral environment for theearly testing and functional verification, and find more bugs as possible in the initial stage ofengine development, to reduce the cost of the development of hareware and software.Meanwhile, we change the Initial configuration of simulation and test platform simply for thetesting of different ECUs, improve the flexibility of the test work greatly; Finally, throughautomatic test procedures, the simulation and test platform can achieve automatic testing. Testengineers configured test cases, the simulation and testing work of the engine ECU can bedone automatically, and generate the test reports automatically, do not need humanintervention during the test. So reduce the workload of the engine ECU simulation and testinggreatly.Relying on deep theoretical research base in intelligent control and embedded systemlaboratory of Jilin University and rich experience and resources of the automotive enginedevelopment in China FAW R&D Center. We presented a complete set of automatic real-time HIL simulation and testing program for automotive engine ECU, and implementedthis automatic real-time HIL simulation and test platform in accordance with the program.The platform had applied in a lot of development projects of engine ECU in China FAW, andit is amenable, and save a lot of development time and labor costs.In the first chapter, I illustrated an overview of the background and significance ofsimulation and testing for automotive engine ECU on the basis of accessing to large amountsof information. So that the reader can understand the importance of the automotive engineECU testing. I described the domestic and overseas research status on this field, and indicatedproblems we face in practical engine development and ECU test engineering. Finally, Isummarized the contents of this research project.The second chapter introduces the basics of simulation and testing of automotive engineECU. Including CAN bus, calibration and calibration protocol, etc. and described itsapplication in the engine ECU test. The same time, illustrate the engine ECU test processthrough the test process of injector ignition, throttle control, knocking processing.The third chapter describes the test principle of engine ECU automatic HIL in detail, anddivide the platform into11modules make it is comprehensible clearly and easier to sort outthe relationship between the various modules. Finally, this chapter describe the overallarchitecture of the automatic HIL simulation and test platform.The fourth chapter describes the hardware architecture and the process to complete theunderlying software of the automatic HIL simulation and test platform. The underlyinghardware including system power, real-time computer, universal I/O board, fault injectionmodules and other components. The underlying software including engine simulation model,I/O board drivers, the hardware and software resources mapping and target machinecontrolled object model. And this chapter describe the process of writing, compiling,packaging the underlying I/O board driver in detail base on sensor analog output signal.Meanwhile, this chapter explain the design process of the interface and allocation of thehardware and software. Also this section illustrate the interface of the control signals and datainteraction between the host machine and the target machine, target machine controlled objectmodel.The fifth chapter depicts the implementation process of the host computer in automaticHIL simulation and test platform and the function of platform. First, this section describes thearchitecture of the host computer and the overall testing process, so that the readers havesome knowledge of it. And then through the test process of sensor analog output signal,describes the process of HIL simulation testing, automatic HIL simulation testing andautomatic generate the test reports in detail.The sixth chapter illustrates the process of debugging and verification of the automaticHIL simulation and test platform, including hardware testing and functional testing. Throughapplied in a lot of development projects of engine ECU in China FAW, we evaluate and verify the functionality and performance of the automatic HIL simulation and test platform. Thischapter describes the verifing function of this platform through the test process of systempower management, analog output signal testing, digital input signal testing, automateictesting, and generate test related documentation and other functions in the actual project.The seventh chapter is the summary and outlook of the whole thesis. Includingsummary of all work of the entire automatic HIL simulation and test, the work which I haddone and achievements. At the same time, summary of the limitations and shortcomings of thework, and the future research prospects.