面向产品工程化的混合动力客车控制系统研究
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摘要
面对能源紧缺问题，以及越来越庞大的城市交通燃油消耗，寻求发展一种低能耗的技术已是急迫的任务。在这种背景下，融合传统燃油汽车和纯电动汽车优点的混合动力汽车成为当今应用前景最广泛的低排放、低能耗汽车。作为一种新型的多能量源城市客车与其他车辆的运行工况相比，具有行驶工况相对固定、平均车速低、载荷多变、高油耗高排放等显著特点，应用混合动力技术实现节能减排更具现实意义。
作为电动汽车的共性关键技术与核心部件，整车控制技术水平直接影响电动汽车整车的动力性、安全性及经济性。目前，国外在电动汽车整车控制器（VCU）开发领域趋于成熟，控制策略成熟度高，整车节能效果良好，控制器产品也通过市场检验证实了其可靠性。国内在整车控制领域与国外还有较大差距，开发多处于功能性开发、节能效果差、缺少足够的测试验证手段以及批量生产管理工具等不足，缺乏面向产品工程化的系统化开发经验。
本文的研究工作是克服以上整车控制系统的不足，面向较为紧迫的控制系统产品工程化开发工作，内容涉及整车建模、能量管理策略开发及测试、工况标定，以及整车批量生产时的下线管理，是一个涉及面较广、较复杂的问题。论文全文包含以下六个方面的内容：
1、通过分析混合动力客车整车控制产业化存在的问题，结合查阅大量的国内外文献资料，梳理了并联混合动力客车控制系统关键技术，确定了论文的研究内容，分析了该问题研究的现状和研究的意义。
2、本文基于商业化仿真软件CRUISE，开展了混合动力客车仿真平台的建模研究，重点开展了CRUISE平台车辆数学建模及处理方法研究，建立了CRUISE-SIMULINK联合的正向仿真平台，为减小仿真与实车的误差，通过与真实试验数据对比分析修正了仿真平台模型从特性及参数，该仿真平台提供了混合动力整车控制及能量管理策略前期验证环境，并为后期的整车性能标定提供理论依据。
3、本文开展了面向工程的混合动力客车整车控制策略研究。在分析整车工作模式的基础上，根据工程约束下的能量管理策略需求，结合产品工程化、模块化要求，在充分分析和研究稳态模式和瞬态模式的能量管理策略基础上，提出了基于规则的多模式分层逻辑规则能量管理策略。
4、混合动力客车系统复杂性导致了整车控制策略测试与验证的难度，为保证混合动力客车在出厂控制系统的可靠性和安全性，本文根据整车控制开发的不同阶段验证需要，开展了从离线仿真、硬件在环仿真、台架试验及整车试验等系统测试与验证研究，满足了产品化控制策略开发可靠性、安全性及开发周期的要求，这些研究为一汽混合动力客车出厂品质提供了保障。
5、本文基于参数模块化和平台化思想，采用基于CAN总线的CCP协议，针对混合动力客车标定需求开发了标定系统。在标定的过程中，采用离线标定（仿真）与在线标定（实车）相结合的先进标定手段，针对实际运行工况开展了大量整车性能标定研究，尤其是针对城市工况解决运行过程中的油耗较高等问题，通过标定取得了较好的效果（以昆明城市工况为例，实现节油5%），此项研究成果推动了一汽混合动力客车产业化推广。
6、根据混合动力客车产品化生产及运行维护需要，开发了功能完备的整车下线检测系统及远程监控系统，所开发的EOL系统大大节约混合动力客车下线时间，提高了生产效率及降低了混合动力客车出厂时的故障率，远程监控系统可以实时监测混合动力客车示范运行状态，提高了面向公交的远程诊断及服务能力。
本文是国家863计划电动汽车重大专项“一汽解放牌混合动力客车新型整车技术开发”及“解放牌中度混合动力客车产业化技术攻关”研究内容的组成部分。论文的研究是面向混合动力汽车整车控制系统产品化实践。为进一步提高混合动力客车整车控制策略的技术成熟度，突破国外技术垄断，形成具有自主知识产权的产品核心竞争能力，更好地满足用户的需求并适应市场需要，进而实现其大规模产业化发展提供技术支持。
论文的创新之处在于基于模块化、平台化开发思想，采用先进的控制系统现代开发方法，实现了测试环境模型搭建、整车能量管理策略开发、控制策略的硬件在环测试、整车标定系统及整车下线检测系统的系统化开发，同时所开发并实际应用的整车下线检测系统，在混合动力汽车生产管理领域属国内首创。
With energy crisis and the increasingly large fuel consumption in the department ofurban transportation, it is an urgent work to develop low energy consumption technology. Inthis context, hybrid electric vehicle which combines the advantages of conventional vehicleand electric vehicle is the most promising low-power and low-emission vehicle nowadays.Compared with other vehicles, urban bus has notable features of relatively fixed drivingconditions, low average velocity, various load, high fuel consumption and high emissions. Soapplication of hybrid technology to achieve energy conservation has more practicalsignificance.
As a common key technology and core component of electric vehicles, the technicallevel of vehicle control system has a direct impact on the power performance, safety and fueleconomy of electric vehicles. At present, the field of development of electric vehicle controlsystem (VCU) abroad tends to be mature that the control strategy is with high maturity,vehicle energy saving performance is notable and the reliability of controller product isconfirmed through market test. There is still a big gap in the field of vehicle controllingbetween domestic and foreign in many aspects such as mostly functional development, badenergy saving effect, the lack of verification and testing instruments, the lack of managementtools for mass production and the lack of experience in developing engineering productionoriented system. The research work of this paper is to overcome the above deficiencies ofvehicle control systems, especially in the urgent task of developing engineering productionof control system. This thesis relates to vehicle modeling, development and test of energymanagement strategy, bench test and vehicle validation, condition calibration and themanagement of vehicle off assembly line in mass production, which covers a wide range andcontain much complexity. The full paper contains the following six aspects.
1. Through analyzing the problem exiting in the industrialization of vehicle controlsystem for hybrid bus, combined with consulting amounts of literature data at home andabroad, this paper sorts out the key technology of parallel hybrid bus control system,determines the research contents, and analyzes the research situation and researchsignificance of this problem.
2. Simulation platform for hybrid electric bus modeling was studied based oncommercial simulation software CRUSE，and the vehicle mathematical modeling andtreatment methods were focused on. A forward simulation platform combined CRUSE andSIMULINK was established. In order to eliminate errors between simulation and real vehicletest, the characteristic and parameters of simulaton platform were modified by analysisingthe difference between simulation results and corresponding real vehicle test data. A basic functional verification environment for early rapid control strategy development of hybridelectric bus or energy management was formed.
3. In this paper, an engineering-oriented control strategy for hybrid electric bus has beenstudied. After analyzing all work modes of hybrid electric bus, the energy managementstrategy was developed based on rule-based multi-mode layered logic rule. And the energymanagement strategy was optimized through bench test and vehicle test.
4. The complexity of hybrid bus system has led to the difficulty of the testing andverification of vehicle control strategy. In order to ensure the reliability and security ofhybrid control system, According to mutative requirement of different stages in the entirevehicle control system development, the offline simulation, HIL simulation and real vehicletest have been carried out in this paper. The requirements of the reliability of product controlstrategy development and the development cycle have been met. And all the researchprovides a quality guarantee for FAW hybrid electric bus.
5. Based on the parameters modular and platform concept, the HCU calibration systemfor the hybrid electric bus is developed with CCP protocol. A CANape calibration tool wasused to complete the calibration research on hybrid electric bus, especially against the highfuel consumption in the city cycle. And the result of calibration shows performancepromotion with5%reduction of fuel consumption, which will push forward theindustrialization of FAW hybrid electric bus.
6. Under the needs of hybrid bus production and operational maintain, a fully functionalvehicle end of line (EOL) detection system and remote monitoring system have beendeveloped. And the EOL system will significantly save the time wasted in hybrid bus off theassembly line, improve production efficiency and reduce the failure rate of the hybrid buses.The remote monitoring system can be real-time monitoring of the hybrid bus demonstrationrun state, which evidently improves bus-oriented remote diagnostics and service capabilities.
This article is part of the research content of electric vehicle major specific projects‘Development of the new vehicle technology of FAW JieFang hybrid bus’ and ‘Research ofthe industrialization technology of JieFang moderate hybrid bus’.The study of this article isfor productization practice of hybrid vehicle control system. In order to further improve thetechnical maturity of the hybrid bus control strategy, to break the technology monopoly offoreign countries, to format core competitiveness of production with proprietary intellectualproperty rights, to better meet the needs of consumers and market, so as to provide technicalsupport of realizing large-scale industrialization development.
The innovation of this article is, based on the developing thought of modularization andplatformization, using the advanced control system developing methods to realize buildingof test environment model, development of the vehicle energy management strategy,hardware-in-the-loop test of the control strategy, systematic development of the vehiclecalibration system and vehicle off-line test system, and the vehicle off-line test system which is developed and applied to reality for the first time in the field of hybrid productionmanagement in China.
作为电动汽车的共性关键技术与核心部件，整车控制技术水平直接影响电动汽车整车的动力性、安全性及经济性。目前，国外在电动汽车整车控制器（VCU）开发领域趋于成熟，控制策略成熟度高，整车节能效果良好，控制器产品也通过市场检验证实了其可靠性。国内在整车控制领域与国外还有较大差距，开发多处于功能性开发、节能效果差、缺少足够的测试验证手段以及批量生产管理工具等不足，缺乏面向产品工程化的系统化开发经验。
本文的研究工作是克服以上整车控制系统的不足，面向较为紧迫的控制系统产品工程化开发工作，内容涉及整车建模、能量管理策略开发及测试、工况标定，以及整车批量生产时的下线管理，是一个涉及面较广、较复杂的问题。论文全文包含以下六个方面的内容：
1、通过分析混合动力客车整车控制产业化存在的问题，结合查阅大量的国内外文献资料，梳理了并联混合动力客车控制系统关键技术，确定了论文的研究内容，分析了该问题研究的现状和研究的意义。
2、本文基于商业化仿真软件CRUISE，开展了混合动力客车仿真平台的建模研究，重点开展了CRUISE平台车辆数学建模及处理方法研究，建立了CRUISE-SIMULINK联合的正向仿真平台，为减小仿真与实车的误差，通过与真实试验数据对比分析修正了仿真平台模型从特性及参数，该仿真平台提供了混合动力整车控制及能量管理策略前期验证环境，并为后期的整车性能标定提供理论依据。
3、本文开展了面向工程的混合动力客车整车控制策略研究。在分析整车工作模式的基础上，根据工程约束下的能量管理策略需求，结合产品工程化、模块化要求，在充分分析和研究稳态模式和瞬态模式的能量管理策略基础上，提出了基于规则的多模式分层逻辑规则能量管理策略。
4、混合动力客车系统复杂性导致了整车控制策略测试与验证的难度，为保证混合动力客车在出厂控制系统的可靠性和安全性，本文根据整车控制开发的不同阶段验证需要，开展了从离线仿真、硬件在环仿真、台架试验及整车试验等系统测试与验证研究，满足了产品化控制策略开发可靠性、安全性及开发周期的要求，这些研究为一汽混合动力客车出厂品质提供了保障。
5、本文基于参数模块化和平台化思想，采用基于CAN总线的CCP协议，针对混合动力客车标定需求开发了标定系统。在标定的过程中，采用离线标定（仿真）与在线标定（实车）相结合的先进标定手段，针对实际运行工况开展了大量整车性能标定研究，尤其是针对城市工况解决运行过程中的油耗较高等问题，通过标定取得了较好的效果（以昆明城市工况为例，实现节油5%），此项研究成果推动了一汽混合动力客车产业化推广。
6、根据混合动力客车产品化生产及运行维护需要，开发了功能完备的整车下线检测系统及远程监控系统，所开发的EOL系统大大节约混合动力客车下线时间，提高了生产效率及降低了混合动力客车出厂时的故障率，远程监控系统可以实时监测混合动力客车示范运行状态，提高了面向公交的远程诊断及服务能力。
本文是国家863计划电动汽车重大专项“一汽解放牌混合动力客车新型整车技术开发”及“解放牌中度混合动力客车产业化技术攻关”研究内容的组成部分。论文的研究是面向混合动力汽车整车控制系统产品化实践。为进一步提高混合动力客车整车控制策略的技术成熟度，突破国外技术垄断，形成具有自主知识产权的产品核心竞争能力，更好地满足用户的需求并适应市场需要，进而实现其大规模产业化发展提供技术支持。
论文的创新之处在于基于模块化、平台化开发思想，采用先进的控制系统现代开发方法，实现了测试环境模型搭建、整车能量管理策略开发、控制策略的硬件在环测试、整车标定系统及整车下线检测系统的系统化开发，同时所开发并实际应用的整车下线检测系统，在混合动力汽车生产管理领域属国内首创。
With energy crisis and the increasingly large fuel consumption in the department ofurban transportation, it is an urgent work to develop low energy consumption technology. Inthis context, hybrid electric vehicle which combines the advantages of conventional vehicleand electric vehicle is the most promising low-power and low-emission vehicle nowadays.Compared with other vehicles, urban bus has notable features of relatively fixed drivingconditions, low average velocity, various load, high fuel consumption and high emissions. Soapplication of hybrid technology to achieve energy conservation has more practicalsignificance.
As a common key technology and core component of electric vehicles, the technicallevel of vehicle control system has a direct impact on the power performance, safety and fueleconomy of electric vehicles. At present, the field of development of electric vehicle controlsystem (VCU) abroad tends to be mature that the control strategy is with high maturity,vehicle energy saving performance is notable and the reliability of controller product isconfirmed through market test. There is still a big gap in the field of vehicle controllingbetween domestic and foreign in many aspects such as mostly functional development, badenergy saving effect, the lack of verification and testing instruments, the lack of managementtools for mass production and the lack of experience in developing engineering productionoriented system. The research work of this paper is to overcome the above deficiencies ofvehicle control systems, especially in the urgent task of developing engineering productionof control system. This thesis relates to vehicle modeling, development and test of energymanagement strategy, bench test and vehicle validation, condition calibration and themanagement of vehicle off assembly line in mass production, which covers a wide range andcontain much complexity. The full paper contains the following six aspects.
1. Through analyzing the problem exiting in the industrialization of vehicle controlsystem for hybrid bus, combined with consulting amounts of literature data at home andabroad, this paper sorts out the key technology of parallel hybrid bus control system,determines the research contents, and analyzes the research situation and researchsignificance of this problem.
2. Simulation platform for hybrid electric bus modeling was studied based oncommercial simulation software CRUSE，and the vehicle mathematical modeling andtreatment methods were focused on. A forward simulation platform combined CRUSE andSIMULINK was established. In order to eliminate errors between simulation and real vehicletest, the characteristic and parameters of simulaton platform were modified by analysisingthe difference between simulation results and corresponding real vehicle test data. A basic functional verification environment for early rapid control strategy development of hybridelectric bus or energy management was formed.
3. In this paper, an engineering-oriented control strategy for hybrid electric bus has beenstudied. After analyzing all work modes of hybrid electric bus, the energy managementstrategy was developed based on rule-based multi-mode layered logic rule. And the energymanagement strategy was optimized through bench test and vehicle test.
4. The complexity of hybrid bus system has led to the difficulty of the testing andverification of vehicle control strategy. In order to ensure the reliability and security ofhybrid control system, According to mutative requirement of different stages in the entirevehicle control system development, the offline simulation, HIL simulation and real vehicletest have been carried out in this paper. The requirements of the reliability of product controlstrategy development and the development cycle have been met. And all the researchprovides a quality guarantee for FAW hybrid electric bus.
5. Based on the parameters modular and platform concept, the HCU calibration systemfor the hybrid electric bus is developed with CCP protocol. A CANape calibration tool wasused to complete the calibration research on hybrid electric bus, especially against the highfuel consumption in the city cycle. And the result of calibration shows performancepromotion with5%reduction of fuel consumption, which will push forward theindustrialization of FAW hybrid electric bus.
6. Under the needs of hybrid bus production and operational maintain, a fully functionalvehicle end of line (EOL) detection system and remote monitoring system have beendeveloped. And the EOL system will significantly save the time wasted in hybrid bus off theassembly line, improve production efficiency and reduce the failure rate of the hybrid buses.The remote monitoring system can be real-time monitoring of the hybrid bus demonstrationrun state, which evidently improves bus-oriented remote diagnostics and service capabilities.
This article is part of the research content of electric vehicle major specific projects‘Development of the new vehicle technology of FAW JieFang hybrid bus’ and ‘Research ofthe industrialization technology of JieFang moderate hybrid bus’.The study of this article isfor productization practice of hybrid vehicle control system. In order to further improve thetechnical maturity of the hybrid bus control strategy, to break the technology monopoly offoreign countries, to format core competitiveness of production with proprietary intellectualproperty rights, to better meet the needs of consumers and market, so as to provide technicalsupport of realizing large-scale industrialization development.
The innovation of this article is, based on the developing thought of modularization andplatformization, using the advanced control system developing methods to realize buildingof test environment model, development of the vehicle energy management strategy,hardware-in-the-loop test of the control strategy, systematic development of the vehiclecalibration system and vehicle off-line test system, and the vehicle off-line test system which is developed and applied to reality for the first time in the field of hybrid productionmanagement in China.
引文
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