Design And Development Of A Hardware-in-the-loop Testing System For Electric-vehicle Based On Virtual Instruments

During the latter part of the20th century, increasing concerns aboutthe environment and rising fuel costs have prompted many OEM’s toswitch gears towards more fuel efficient vehicles. Major developmentshave been made towards to energy system, motors， motor controllers,Battery and control strategy such as EBD and BMS in recent years.In order to test the core components and verify the control strategy forEV/HEV, a HIL test bench was developed to provide a real environmentbased on three dynamometers. Testing functions can be achieved by thehardware and software configurations, such as the transmissionperformance test, engine emulation and hybrid drivetrain performance test.This bench was designed to meet different requirements.First the hardware and software program was proposed and theadvantage and disadvantage of the bench was analyzed. Then in thispaper based on the configured parameters, a whole testing bench controlmodel was developed, especially the EV dynamic model and the controlstrategy. The drive dynamometer synchronization in up-and-down shifting process and braking energy regeneration process was also taken intoaccount. The results show that the designed shift strategy achieved a betterenergy efficiency and comfort riding.Finally the model was deployed into a RT controller and was mappedwith the Hardware I/O. The communication of the HIL system was verifiedby testing cards.