Research On ECU Hardware-in-the-Loop Test Evaluation For Electronic Stability Control Of A Car

Electronic Stability Control(ESC) ensures that vehicle’s traveling track is inaccordance with the driver’s desired driving intent by monitoring vehicle’s running states,comparing the actual track of vehicle with the driver’s desired traveling track, and makingdecision how to adjust the wheel cylinder pressure and the engine output torque based onthe difference between the two. Due to the significant role played by ESC in improvingvehicle active safety, people’s research enthusiasm to ESC remains undiminished, ESC hasbecome a hot research area in the field of vehicle dynamics. In foreign countries, includingAmerica, Canada, European countries have formulated relevant laws and regulations ofcompulsorily equipping vehicles with ESC, and corresponding test evaluation criterion aregiven. But at present our country only formulate GB/T13594-2003test criteria for anti-lockbraking function, other regulations or test evaluation criterion related to ESC hasn’t yetbeen formulated or issued, so there is a lot of work to do for research on ESC.At present, the test evaluation based on hardware-in-the-loop simulation technique hasbecome the main measure for automobile manufacturers and suppliers testing and verifyingthe performance of ESC. Although real vehicle road test is the most direct and effectiveevaluation of ESC performance, many factors will limit the application of real vehicle roadtest in practice, such as the requirements for experimental condition, the danger of test andthe repeatability of test, and it leads to part of real vehicle test gradually being replaced byhardware-in-the-loop simulation test. In terms of the status quo of domestic automobilemanufacturers, domestic new cars equipped with ESC are provided by foreign suppliers, inorder to verify the function of suppliers’ ESC in accordance with the function definitionduring the developing stage of a new car, but also to prevent ESC emerging defects when itis in use, domestic automobile manufacturers need to conduct hardware-in-the-loop tests ofESC during the developing stage of a new car, find and solve problems as soon as possible, thus avoiding recall issue after a new car enters into market due to ESC problems. As far asESC hardware-in-the-loop simulation test, we need to establish test evaluation systembased on hardware-in-the-loop simulation technique, so as to provide theoretical guidanceand technical support for conducting the entire simulation test.This thesis, combined with ESC ECU test project of an enterprise, makes research onthe target ESC ECU hardware-in-the-loop test evaluation. This thesis mainly carries out thefollowing research work:(1)Analyze the current situations of hardware-in-the-loop simulation technique, ESChardware-in-the-loop test bench, ESC test evaluation methods. Combined with researchobject of this thesis-ESC ECU, propose the overall architecture of ESC ECUhardware-in-the-loop test evaluation system. Then in turn define the function of its variousmodules and make a brief introduction.(2)Propose the overall program of ESC ECU hardware-in-the-loop test platform, andmake a brief analysis and introduction of operating principle and compositions of hardwareand software of the test platform. Then divide the construction of the test platform into twoaspects, one is the hardware design, the other is software design. In terms of hardwaredesign, the specific work includes introduction of dSPACE real-time simulation system andhardware selection, program design of vehicle attitude simulation test bench and analysis ofsimulation principle, the Hall sensor mounting position and magnetic saturationperformance test, design of valve coil signal detection module and development of signalprocessing circuit, etc. Then, in terms of software design, this thesis firstly introduceMatlab/Simulink simulation environment, CarSim vehicle dynamics simulation softwareand real-time interface RTI software environment. Then build IO interface model based onMatlab/Simulink, design of ControlDesk test management surface, develop vehicle attitudesimulation test bench controller based on fuzzy PID theory. On this basis, the controllerwas conducted off-line simulation and hardware-in-the-loop simulation, and simulationresults show that the controller can achieve better control effect.(3)Through referring to domestic and foreign criterion, summarize test evaluation criterion in relation to domestic and foreign automobile active safety. And make a detailedintroduction of which are relevant to ESC control function test evaluation criterion,including specific test methods, evaluation criterion, etc. Then, combined domestic andforeign ESC control function test evaluation criterion and performance requirements of thetarget ESC, identify control function test evaluation methods of ESC ECU hardware-in-the-loop in the thesis. In terms of research on fault diagnosis function test evaluation, firstlyanalyze foreign automobile fault diagnosis criterion. Then, classify fault diagnosisprotocols which are applied on the ESC, and make a brief introduction of foreign methodsin relation to ESC fault diagnosis function test evaluation according to the classification.Finally, identify fault diagnosis function test evaluation methods of ESC ECUhardware-in-the-loop in the thesis.(4)Based on the control function test platform and the fault diagnosis function testplatform, make use of simulation test conditions and evaluation criterion previouslyidentified for testing and evaluating control function and fault diagnosis function of ESCECU. The test evaluation results not only prove the validity of ESC ECUhardware-in-the-loop test evaluation system which is the established in the thesis, but alsofurther validate the effectiveness of ESC ECU hardware-in-the-loop test platform.