HIL Simulation of Hybrid Control Units

Testing distributed functions

Hybrid drivetrains combine well-known state-of-the-art powertrain technology with powerful electric motors and storage devices in various configurations. Compared to traditional powertrains, electric traction drives, and electric auxiliaries add additional degrees of freedom to the system with regard to functionality and packaging, which leads to a more complex and distributed control system (hardware and software).
Unlike tests on a single component ECU, tests on an overall powertrain control system have to take the various connections between the devices under test into account (combustion engine, transmission, electric motors, battery management, etc.). These devices may be coupled by controller networks (CAN, LIN or FlexRay bus) or by electrical and mechanical systems, which have to be covered by the system model.

Application Areas

  • Testing network communication between networked ECUs
  • Integration testing
  • Testing distributed functions in the ECU network
  • Testing network communication between electric vehicles (EV) and electric vehicle supply equipment (EVSE) according to CHAdeMO, ISO 15118, GB/T 18487, etc.

Key Points

  • Modular network of two or more SCALEXIO simulators
  • Extension to full virtual vehicle by adding additional SCALEXIO systems
  • Automotive Simulation Models for all plant components
  • Building of two or more parallel CAN structures for a typical realistic hybrid powertrain structure
  • Restbus simulation of unavailable components
  • Configuration of all known hybrid and electric vehicle versions, ECUs, and CAN configurations
  • Decentralized setup of simulators possible

The networked SCALEXIO system comes with at least one Processing Unit for computing the simulation models. Large, complex simulation models can be distributed across three or seven processor cores (depending on the version) to ensure that they can be computed in real time. One core is reserved for internal system services. If required, additional Processing Units can be integrated. To distribute model parts to the cores and to configure the communication behavior, simulation hardware and model connections, you can use ConfigurationDesk.

Specialized interface hardware provides functions such as signal generation and measurement, failure simulation, and communication connections. The test scenario also covers several CAN, FlexRay and Ethernet networks as well as restbus simulation if not all components are available. The modularity and flexibility of the SCALEXIO hardware enables you to add more racks to cover all the other ECUs in the vehicle, such as the ESP ECU.

For testing distributed functions within an ECU network, buses and networks play a major role. One of the strengths of the dSPACE SCALEXIO HIL simulator is simulating communication networks. The system is able to simulate complex models, buses, and networks under real-time conditions. For communication tests, the most common modern communication standards are supported, such as CAN, LIN, FlexRay, and Ethernet.

A high number of ECUs and ECU variants results in a high number of different models used for HIL simulation.

Handling the ECU versions and variants is simplified significantly by dSPACE Workflow Management based on dSPACE SYNECT. It lets you centrally and conveniently configure all the information necessary to support your workflows in SYNECT and manage large, highly complex HIL systems with a high number of variants and multiple software interactions.

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