Research And Implementation Of ECU Hardware-in-the-loop Test System For High Pressure Common Rail Diesel Engine

Diesel engine with high specific energy,wide range of speed and power,reliable and durable,economical and other advantages which plays an extremely important position in the power system.In order to further realize the energy-saving and emission-reduction of diesel engine,diesel engine electronic control mode which based on the embedded control system and sensors replaces the traditional mechanical control mode has become an effective way to improve the comprehensive performance of the diesel engine.To meet the increasingly stringent emission regulations,as well as the market consumers on vehicle safety,operability and comfort of the higher demand,the structure and control strategy of electronic control unit ECU of high pressure common rail diesel engine are more and more complex,and the control precision is higher and higher.All these have greatly increased the difficulty and periodicity of debugging ECU development on traditional test bench.The debugging environment is unstable or difficult to achieve,which requires huge human and material resources,and unable to meet the dual needs of the modern ECU development quality and efficiency.Therefore,the paper based on the hardware-in-the-loop technology as the core,and built a hardware and software is highly coupled,integrated real-time simulation test system for the ECU to which provides a comprehensive realistic virtual test environment,reduces the ECU development and debugging of the bench test dependence and uncertainty of risk,reduces resource investment at the same time,improves the development efficiency.In this paper,the knowledge of diesel engine electronic control system is discussed,and proposes the necessity of constructing ECU hardware-in-the-loop simulation test system.Firstly,this paper introduces the principle and application form of hardware-in-the-loop simulation technology,and analyzes the current research situation at home and abroad.Secondly,it makes a comparison with existing sets of practical product design and combines with the existing laboratory hardware condition and technology base,and use the NI virtual instrument software and hardware platform to build a good scalability and strong applicability overall design of the program.The NI CompactRIO real-time controller is equipped with the virtual diesel engine model to complete the rapid simulation calculation,and the man-machine interface vector PC to realize the data exchange with the controller via Ethernet,and the signal I/O interface uses the NI board to achieve signal conversion,acquisition and processing.Based on the NI LabVIEW software development environment,the software function of the real-time dynamic model of the diesel engine,the man-machine interface,the signal conversion program and the signal fault are designed and realized.While the hardware-in-the-loop system embedded in the real high-pressure common-rail fuel injection system,the fuel injection system under virtual diesel engine simulation speed controls servo motor to drive pump.Then,the matching diesel engine operating condition is completed,which is according to the vehicle load model.The characteristics of ECU input signals are analyzed and the diesel engine state signal conversion model such as crankshaft,camshaft,accelerator pedal position and coolant temperature are established.On this basis,built the system project and integrated function module to constitute the hardware in the loop simulation test system.In the end,the paper carry out a whole joint debugging for the hardware-in-the-loop test system platform which is designed independently,and verified the real-time response and accuracy of each part of the system.It can reproduce the real different working conditions of diesel engine.Through the simulation testing of functionality,reliability and fault status of the ECU shows that the been designed and developed hardware-in-the-loop system has strong function and good applicability,and which achieves the expected design target.