基于硬件在环的电动汽车整车控制器功能测试方法研究

基于硬件在环的电动汽车整车控制器功能

测试方法研究

Research on Functional Test of Vehicle Controller of Electrical Vehicles Based on

Hardware in the Loop

学科专业：动力工程

研 究 生：夏锌

指导教师：谢 辉 教授

企业导师：周能辉 高工

天津大学机械工程学院

二零一三年十二月

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摘 要

“三电技术”（电机、电池及电控技术）是电动汽车的关键技术，整车控制器作为电控系统的核心，其开发遵循汽车电子的标准V-Cycle流程。硬件在环（HIL）作为V-Cycle中的重要一环，可以全面验证整车控制器的功能。 整车控制器软件系统可以分为底层和应用层，底层软件是应用层软件各种功能的载体，功能较为简单，测试过程重复劳动较多；应用层软件功能复杂，测试工作量较大，需要系统的方法提高测试效率降低测试成本。针对这些问题，本文开发了用于底层软件的自动化测试系统；提出了整车控制器功能测试模型，并将输入量离散化进一步减少测试用例数量。这些方法在整车控制器的开发过程中得到了应用，提高了测试效率，降低了测试成本。具体工作包括：

提出了硬件在环系统生命周期模型。介绍了整车控制器的开发流程以及功能，阐述了硬件在环的原理与基于dSPACE的整车控制器硬件在环系统，划分了硬件在环系统生命周期的五个阶段。

开发了底层软件自动化测试系统。为了减少底层软件测试的工作量，提出了底层软件接口自动化测试方法，并给出了Python脚本的实现过程。

构建了用于应用层软件功能测试的HIL环境。利用Matlab/Simulink软件并合理划分模块，搭建了电动汽车对象模型且实现参数化管理。搭建了Controldesk测试管理界面，并对整个环境进行了验证。

搭建了整车控制器功能测试模型，提出了测试输入量离散化方法。基于需求文档并利用状态机搭建了整车控制器功能测试模型，同时提出了利用等价类划分方法、边界值分析方法离散化输入量，并且给出了利用Python语言的实现方式。此外，部分测试用例需要设置故障，因此介绍了基于dSPACE DS291板卡的故障注入测试。

提出的方法在整车控制器的开发中得到了应用，底层软件自动化测试能够节省90%的时间，应用层测试环境能够很好地模拟实车全面测试整车控制器，应用层测试方法能够以较少的测试用例达到功能覆盖率。

关键词： 纯电动汽车 整车控制器 硬件在环 功能测试

ABSTRACT

Motors, batteries and electric control are the key technologies of electric vehicles. As the core of the electric control system, the development of vehicle controller follows the standard V-Cycle process of automotive electronics. Hardware in the loop (HIL), which plays an important role in V-Cycle, is able to fully verify the function of the vehicle controller.

The vehicle controller software system can be divided into the low-level layer and the application layer. The low-level software is the carrier of the application layer software functions, whose function is relatively simple and involves massive duplication work during the testing process. The application layer software has relatively complex function with heavy testing work. Consequently, a system method should be applied to improve test efficiency for reducing test cost. To solve these problems, automatic testing system used in the low-level software is developed. Besides, the vehicle controller function test model and test case automatic generation software is proposed. These methods mentioned above have been applied in the vehicle controller development process, resulting an improvement in test efficiency and reduction in the test cost. The specific work is summarized as follows:

The HIL system lifecycle has been put forward. This present work introduces the development process and function of the vehicle controller. The HIL system and its principle in the application of vehicle controller based on dSPACE is presented. The building process of HIL system must be standardized and the system has to be maintained during the implementation. Therefore, the hardware in loop system lifecycle model is proposed.

In order to reduce the workload of the low-level software testing, an automatic test method of the low-level software interface is put forward. Then a HIL environment for testing the function of application layer is built by Matlab/Simulink software, with the module divided reasonably. An object model of electric car is built and the parameterized management is realized. After that, a Controldesk test management interface is built to verify the whole environment.

A vehicle controller function test model is built by the implementation of the state machine based on the requirement documents, and method of discretization of inputs

is proposed. The discrete inputting method is based on the equivalence class partition method and boundary value, which is realized and implemented by Python In addition, considering that fault has to be set in some test cases, the fault injection test based on dSPACE DS291 board is introduced.

KEY WORDS：Electrical vehicles, Vehicle controller unit, Hardware in the loop, Functional test

目 录

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