Design And Implementation Of Hardware-in-the-loop Simulation Test System For Electric Vehicle Range Extender Controller

Range extender is one of the core components of the Range-extended electric vehicle.It will generate electricity when the power battery of electric vehicle is low,maintain the power balance,and achieve the purpose of increasing the driving range.The "core brain" of the range extender is range extender controller which is the key component to realize the safe operation and efficient power generation.Hardware in the loop simulation test is one of the important links in the V-mode development process of automotive electronics.The hardware in the loop simulation test system for the range extender controller can effectively improve the development efficiency,reduce the development cost,and greatly improve the security and reliability of the controller.Firstly,this paper analyzes the overall structure of the range extender,the internal strategy and hardware circuit of the controller to complete the overall scheme design of the hardware in the loop simulation test system of the range extender controller based on the Simulink Real-Time software provided by MathWorks company.Then,according to the overall scheme,the controlled object model of the range extender required by the test system is developed.Considering the requirements of model accuracy and calculation efficiency,the engine model,generator model and their coupling model are built by combining physical modeling method and test data modeling method.After completing the modeling work,the corresponding steady-state test is designed for the look-up table module in the model to obtain the look-up table parameters.The corresponding dynamic test is designed for other unknown parameters.Using the test data,the parameter identification is carried out according to the nonlinear least square method.For the identified model,corresponding dynamic tests are designed to verify it.The verification results show that the physical output of the model is in good agreement with the range extender bench test results.The steady-state relative error of each physical quantity output of the controlled object model of the range extender is basically kept within 10%,and the dynamic relative error is basically kept within 15%.Finally,the hardware in the loop simulation test system of the extender controller is built based on the controlled object model of the range extender.The range extender bench test and the hardware in the loop simulation test under the same control strategy are designed.The simulation results are verified by the bench test data.The results show that the physical output of HIL system has high simulation accuracy.The relative errors of torque and rotating speed are basically kept within 10%.The steady-state relative errors of generator current and power are basically kept within 5%,and the dynamic relative errors are basically kept within 15%.