1.Summary

1.1 At present, the environmental protection drive technology represented by hybrid electric vehicle and pure electric vehicle is in the stage of rapid development. As the power source of electric drive system, the charging and battery management technology of on-board power battery pack has become the focus of research. Through the hardware in the loop simulation, the test platform can be built quickly with low cost and high efficiency, which becomes an important link in the process of pre research and development.

1.2 The bms-hil hardware in the loop real-time simulation test adopts the real controller, and the controlled object and system running environment adopt or partially adopt the real-time simulation model to realize the simulation test of the whole system, which can effectively improve the software quality and reduce the potential risk of BMS control function while shortening the development cycle and reducing the cost of BMS control strategy.

1.3 The core system consists of three main parts: operation interface, real-time processor and I/O interface board.

1.4 Real time processor is the core of HIL test system. It provides deterministic execution of most HIL test systems, such as hardware I/O communication, data recording, stimulus generation, and model execution.

1.5 I/O interfaces are analog, digital and bus signals that interact with the components under test. They are used to generate excitation signals, obtain data for recording and analysis, and provide sensor / actuator interaction between the tested BMS and the virtual environment of model simulation.

1.6 The operation interface communicates with the real-time processor to provide test commands and visualization. In most cases, this component also provides configuration management, test automation, analysis, and reporting tasks.

1.7 CARSIM_ BMS hardware provides a modular and configurable platform for different battery input signals, such as the number of battery cells, sensors, IO signals, and the communication needed to simulate the BMS test environment.

1.8 The system can be configured with multiple high voltage programmable power supplies to simulate internal and external high voltage. The power supply is connected with PXI host through CAN bus, and the voltage output value can be adjusted directly in the upper computer software.

1.9 The battery simulation unit adopts the test products specially designed for hybrid electric vehicles and pure electric vehicles launched by the joint instrument. Through CarSim upper computer model programming, it can accurately simulate the charging and discharging process of lithium battery, Ni MH battery and other batteries. It can simulate each state of the cell, trigger the high voltage fault handling, under voltage fault handling and differential pressure fault handling of BMS, Balance test.

1.10 RS-100 programmable resistance box is a programmable impedance simulation box developed by yidingfeng company, which can be used to provide analog impedance for BMS insulation detection function test.

1.11 The output of resistance box impedance is controlled by upper computer, and the impedance can be set as short circuit, open circuit and 100 Ω～ 65.536M Ω Three states can be adjusted. The resistance box informs the user of the current set impedance state through the LCD display.

2.Test management Software

2.1 With Ni veristand as the core, connected with real-time processor through Ethernet, and developed with LabVIEW, TestStand, MathWorks Simulink and other rich function expansion packages.

2.2 The system is a modular and configurable platform, which is used to meet different battery input signals, such as the number of battery cells, sensors, IO, and communication needs to simulate the BMS test environment.

2.3 The main functions of the experiment management software include: hardware configuration management, simulation model import, hardware I / O mapping, I / O interface configuration, calculation channel and event alarm, fault signal simulation, user interface creation, test incentive generation, automatic test sequence writing, data recording and playback, automatic test execution and report generation.

3.Advantages Of Testing Solutions

3.1 Real time simulation hardware based on high configuration

(1) It has powerful model calculation ability, and can complete the calculation of the whole vehicle simulation model on one RTPC. In this way, the debugging difficulty and real-time synchronization problem of multiple model computing devices are avoided.

(2) PXI architecture provides an open interface, in which the buyer can integrate self-developed or third-party software and hardware to achieve special functions with high cost performance.

3.2 Cost effective can bus test node

(1) Each can bus port can be individually set to use high speed can or low speed can for communication.

(2) It can easily manage the remaining network simulation.

3.3 White box test seamlessly connected with Inca: it can be seamlessly connected with canape and Inca measurement and calibration system, changing black box test into white box test, reaching unprecedented test breadth and depth.

3.4 High standard vehicle signal generation and measurement

(1) Ni hardware board provides higher precision, larger output current and larger input impedance to meet the needs of high-performance system.

(2) All the main cards are imported directly from the United States, and the quality can ensure the stability and durability of the system.

3.5 easy to expand modular product components

(1) Professional modular products, such as I / O board box, RTPC, fault injection unit, Bob, standard load simulation box, etc.

(2) Simplify the system integration work, speed up the debugging and operation time, speed up the project switching speed.

(3) It is easy to standardize the wiring harness, which makes the cabinet layout and internal connection more reasonable.

(4) Users can easily expand and upgrade the system by adding modules and wiring harness.

3.6 Professional compact fault simulation module: enables users to carry out real-time fault simulation. Besides short circuit and open circuit, it also provides fault modes such as leakage current, virtual connection and jitter.

3.7 Strict separation of simulation model and hardware interface

(1) When only adjusting the hardware interface without changing the model structure, there is no need to call matlab to compile, which saves valuable time in the system debugging stage.

(2) Transfer the simulation model on different hardware platforms without changing the content of the model itself.