Development Of Vehicle Control Unit Hardware-ln-Loop Testing System And Calibration System

As the control center of control system in pure electric vehicle, vehicle control unit(VCU) is important for the safety, stability, reliability of vehicle. In the development ofVCU process, it is essential to pass the hardware-In-Loop (HIL) testing and calibrationsteps for VCU. So the development of HIL testing and calibration system has becomemore important nowadays.The HIL testing has been developed based on the xPC-Target. The HIL testingsystem can simulate the running environment around VCU, inputs signals to VCU andreceives the output signals of VCU. At the same time, the CAN messages can be sent andreceived between the designed system and VCU. In the process of testing drive controlstrategy, the model of vehicle built by Simulink can be run in xPC-Target after beingcompiled to simulate the vehicle controlled by VCU. So the testing procedure of drivecontrol strategy can be validated. In addition, the calibration system has to be developedin order to change and monitor the parameters in VCU. By combining the HIL andcalibration system, the key control parameters in VCU can be acquired and measuredeasily, then the control effect of drive control strategy and driving performance can beimproved.Considering the project researching, the following contents are included in thispaper:(1) Firstly, the software and hardware interfaces of VCU are summarized, so thetesting items of HIL are definite. Considering the components of testing and calibrationsystem, the overall architecture of HIL and calibration testing system is clarified basedon the demands of VCU testing and calibration.(2) According to the system architecture, the software and hardware implementationmethod has been proposed in the testing process of IO and drive control strategy. It is about the selection of PC, xPC-Target, Data Acquisition Card (DAQ), CAN Card and theprogrammable power supply module. The design of signal conditioning board andself-check board can be needed. In the aspect of software, it includes the development ofDAQ driver and power supply driver, building the testing module and vehicle model byusing Simulink and the interactive interfaces between human and machine.(3) The VCU calibration system based on CCP protocol is designed in order tochange the parameter in VCU real-time and display the DAQ parameters. As therealization of CCP protocol are through CAN communication, so the USBCANequipment can be enough to exchange information between ECU and PC. Thedevelopment of software is that the CCP driver development, the combination of CCPdriver and application program in the end of ECU. In the end of PC, the development ofCCP driver and calibration control desk. Especially, the pack and unpack module ofASAP2file is very important in getting the memory address of specific parameter inECU.(4) The development of system has been done then the sub-modules including theDAQ driver and power supply module driver can be tested. The IO testing, drive controlstrategy testing and the calibration performance are verified. Utilizing HIL andcalibration system to adjust and test the parameters in purpose of optimizing the drivecontrol effect and verifing the integrated performance of HIL and calibration.