客车AMT_TCU及混合动力客车HCU测试系统的研制
摘要
针对客车AMT_TCU和混合动力客车HCU硬件测试的需求,本文提出了一种自动化的测试系统,并详细介绍了测试系统相关的软硬件设计。
测试系统可以由上位机对各种信号进行控制(程控模式),也能够在没有上位机发送控制命令的情况下按照自身设计的控制逻辑进行全自动工作(预定义模式),将测试信息发送给PC机进行保存。可以通过CAN总线与TCU/HCU通讯,通过特定协议控制TCU/HCU采取相关动作和读取TCU/HCU返回的各种信息。
能够提供TCU和HCU测试所需要的各种输入信号,包括模拟量信号、开关量信号、车速脉冲信号、差分式正弦波信号;能够提供TCU和HCU各种驱动信号所需要的负载,并检测驱动信号的工作情况;能够提供与TCU和HCU通讯的CAN接口。测试系统能将被测样品的工作信息发送给PC机,进行显示和相关数据的处理、存储。
该系统提高了TCU和HCU硬件测试的自动化程度,增加了测试结果的客观性和准确性。
In recent years, because of the growing recognition of the good performance of AMT, many domestic automobile enterprises have quickened the pace of development of the AMT. The electronic control system is AMT's core technology and hardware basic, The design of the electronic control system will have a direct bearing on the quality of the AMT. Electronic control systems are generally divided into signal input device, the electronic control unit and implementation agencies.
Environmental protection and energy conservation is the development of the two major themes of the automobile industry; focus on the two major themes, countries competing in the development of the "green" vehicles, electric vehicles as one of the main solutions. Which traditional car's engine and electrical power source for cars - hybrid vehicles (Hybrid Electric Vehicle, HEV) have emerged as the most current electric vehicles with the industrialization and marketization of the prospects of one of the models. Hybrid Electric Vehicle Controller HCU contacts with the other assembly control unit is the key part of hybrid car. Usually vehicles has a poor and changeable working environment, to ensure that the vehicle electronic control system can work reliably in the weather, mechanical, electrical performance under all conditions, we the need to test the complete reliability in variety of environmental after the development of products. However, in the TCU or HCU hardware failure tests, it is difficult to issue the original car signal and the various electromagnetic valves, relays, etc. for the tests. At past the hardware testing of TCU and HCU, is mainly used load-box. Such tests require operators to switching all loads and signals continually, it's tedious and have great impact of human factors; The preservation of the data of the testing process is manual,it go against the data archive management. It is very important to develop an automated testing system, which does not require operators.
This paper in response to the TCU and HCU of the FAW R&DC,discussed in detail about the design of the test system's hardare and software, including hardware and software architecture design, the main hardware components and operating principle , design a test system that including the input signal,simulated the load and can communicat with TCU/HCU by CAN bus. System communicats with the computer by PCI to CAN card of National Instruments, PC using the graphical programming environment LabVIEW7.0 virtual instrument for the development of the control interface development tools. System hardware according to the signal flow is divided into two 16-bit MCU with dsPIC30F6014A control modules: the signal input modules, the signal output unit and a load module.
Signal output unit responsible for the provision of TCU / HCU for 0 to 5 V analog, 0 and 24 V Switch (fluctuations of 16 to 32 V), speed pulse signal, the differential input sine wave signal, a CAN bus interface for TCU/HCU and a K-LINE interface for HCU.
Test system using 12-bit D/A converter chip DAC7614 combined with external circuit to produce analog, MCU through the I/O ports and voltage-conversion circuits produce switch, use the output compare module to produce the pulse signal,.Based on the address counter direct digital synthesis,system can produce sinusoidal signal.
Signal input unit will be responsible for the processing and acquisition of the signal detected by load unit, provided another CAN bus interface for TCU/HCU and a K-LINE interface for HCU.
Load unit responsible for the detection of TCU/HCU electromagnetic valve drive signals and relay driving signals. Through the inductance and the resistance to simulate the car's true electromagnetic valve, as a TCU drive signal load. In order to reduce the testing process on the electromagnetic valve drive signals, we use current sensor to collect the current through the load. Relay drive signal directly select the same parameters as the load. The state of TCU/HCU sent to the test system by CAN bus; the units of the system and the PC have become a multi-node network of CAN. Therefore CAN communication design is the difficulty and keystone of this system. According to the needs of system design, we have formulated relevant CAN communication application layer protocol.
System control software is designed to CAN communication structure at the core, use structured programming design method, software modules and hardware modules are relative, includes output signal (switch, analog, speed, engine speed) generated modules, drivers signal detection module electromagnetic valves, relays), communications interface modules. Test system achieved the target that the signal can be controlled by PC, system can automatically work by the designed logic.
Test system has been applied on the TCU/HCU hardware fault detection, the results said that the functions, the stability, reliability, output quality and drive signal detection and CAN communications satisfied the TCU/HCU test requirements. Finally, this paper summarizes the application of the test system and makes some further improvements.
测试系统可以由上位机对各种信号进行控制(程控模式),也能够在没有上位机发送控制命令的情况下按照自身设计的控制逻辑进行全自动工作(预定义模式),将测试信息发送给PC机进行保存。可以通过CAN总线与TCU/HCU通讯,通过特定协议控制TCU/HCU采取相关动作和读取TCU/HCU返回的各种信息。
能够提供TCU和HCU测试所需要的各种输入信号,包括模拟量信号、开关量信号、车速脉冲信号、差分式正弦波信号;能够提供TCU和HCU各种驱动信号所需要的负载,并检测驱动信号的工作情况;能够提供与TCU和HCU通讯的CAN接口。测试系统能将被测样品的工作信息发送给PC机,进行显示和相关数据的处理、存储。
该系统提高了TCU和HCU硬件测试的自动化程度,增加了测试结果的客观性和准确性。
In recent years, because of the growing recognition of the good performance of AMT, many domestic automobile enterprises have quickened the pace of development of the AMT. The electronic control system is AMT's core technology and hardware basic, The design of the electronic control system will have a direct bearing on the quality of the AMT. Electronic control systems are generally divided into signal input device, the electronic control unit and implementation agencies.
Environmental protection and energy conservation is the development of the two major themes of the automobile industry; focus on the two major themes, countries competing in the development of the "green" vehicles, electric vehicles as one of the main solutions. Which traditional car's engine and electrical power source for cars - hybrid vehicles (Hybrid Electric Vehicle, HEV) have emerged as the most current electric vehicles with the industrialization and marketization of the prospects of one of the models. Hybrid Electric Vehicle Controller HCU contacts with the other assembly control unit is the key part of hybrid car. Usually vehicles has a poor and changeable working environment, to ensure that the vehicle electronic control system can work reliably in the weather, mechanical, electrical performance under all conditions, we the need to test the complete reliability in variety of environmental after the development of products. However, in the TCU or HCU hardware failure tests, it is difficult to issue the original car signal and the various electromagnetic valves, relays, etc. for the tests. At past the hardware testing of TCU and HCU, is mainly used load-box. Such tests require operators to switching all loads and signals continually, it's tedious and have great impact of human factors; The preservation of the data of the testing process is manual,it go against the data archive management. It is very important to develop an automated testing system, which does not require operators.
This paper in response to the TCU and HCU of the FAW R&DC,discussed in detail about the design of the test system's hardare and software, including hardware and software architecture design, the main hardware components and operating principle , design a test system that including the input signal,simulated the load and can communicat with TCU/HCU by CAN bus. System communicats with the computer by PCI to CAN card of National Instruments, PC using the graphical programming environment LabVIEW7.0 virtual instrument for the development of the control interface development tools. System hardware according to the signal flow is divided into two 16-bit MCU with dsPIC30F6014A control modules: the signal input modules, the signal output unit and a load module.
Signal output unit responsible for the provision of TCU / HCU for 0 to 5 V analog, 0 and 24 V Switch (fluctuations of 16 to 32 V), speed pulse signal, the differential input sine wave signal, a CAN bus interface for TCU/HCU and a K-LINE interface for HCU.
Test system using 12-bit D/A converter chip DAC7614 combined with external circuit to produce analog, MCU through the I/O ports and voltage-conversion circuits produce switch, use the output compare module to produce the pulse signal,.Based on the address counter direct digital synthesis,system can produce sinusoidal signal.
Signal input unit will be responsible for the processing and acquisition of the signal detected by load unit, provided another CAN bus interface for TCU/HCU and a K-LINE interface for HCU.
Load unit responsible for the detection of TCU/HCU electromagnetic valve drive signals and relay driving signals. Through the inductance and the resistance to simulate the car's true electromagnetic valve, as a TCU drive signal load. In order to reduce the testing process on the electromagnetic valve drive signals, we use current sensor to collect the current through the load. Relay drive signal directly select the same parameters as the load. The state of TCU/HCU sent to the test system by CAN bus; the units of the system and the PC have become a multi-node network of CAN. Therefore CAN communication design is the difficulty and keystone of this system. According to the needs of system design, we have formulated relevant CAN communication application layer protocol.
System control software is designed to CAN communication structure at the core, use structured programming design method, software modules and hardware modules are relative, includes output signal (switch, analog, speed, engine speed) generated modules, drivers signal detection module electromagnetic valves, relays), communications interface modules. Test system achieved the target that the signal can be controlled by PC, system can automatically work by the designed logic.
Test system has been applied on the TCU/HCU hardware fault detection, the results said that the functions, the stability, reliability, output quality and drive signal detection and CAN communications satisfied the TCU/HCU test requirements. Finally, this paper summarizes the application of the test system and makes some further improvements.
引文
[1]庞学文.任意波形发生器的研制.吉林大学.2005
[2]刘明辉.混合动力客车整车控制策略及总成参数匹配研究.吉林大学博士学位论文.2005.
[3]侯培国,韩向芹.电控机械式自动变速器控制系统的研究.传感技术学报.2005年02期
[4]邬宽明.CAN总线原理和应用系统设计 北京航空航天大学出版社2001.3
[5]蔺京敏.基于P87C591单片机的CAN总线应用层协议的研究.河北工业大学.2004
[5]桑楠.嵌入式系统原理及应用开发技术.北京航空航天大学出版社2002.4
[6]吴晓刚,邢学刚,胡冰山,王瑛,王旭东.基于DSP无级变速箱控制单元的输入信号模拟.哈尔滨理工大学学报.2005年04期
[7]江发潮.汽车AMT电控单元虚拟试验系统的研究.中国农业大学博士学位论文.2003年
[8]温明.现代汽车中的电控技术.汽车技术.1995年2期
[9]牛洪涛.印制电路板的可靠性设计.电子制作.1998年01期
[10]葛安林.车辆自动变速理论与设计.机械工业出版社.1993.5
[11]陈德阳.自动变速器试验台研究.吉林大学硕士学位论文.2003
[12]蔡伟义,李贵炎.自动变速器试验台的研制.客车技术与研究.2003年6期
[13]于海生.CAN总线工业测控网络系统的设计与实现.仪器仪表学报.2001年01期
[14]阳宪惠.现场总线技术及其应用.北京清华大学出版社.1999
[15]dsPIC30F系列参考手册.Microchip Technology Inc.2005
[2]刘明辉.混合动力客车整车控制策略及总成参数匹配研究.吉林大学博士学位论文.2005.
[3]侯培国,韩向芹.电控机械式自动变速器控制系统的研究.传感技术学报.2005年02期
[4]邬宽明.CAN总线原理和应用系统设计 北京航空航天大学出版社2001.3
[5]蔺京敏.基于P87C591单片机的CAN总线应用层协议的研究.河北工业大学.2004
[5]桑楠.嵌入式系统原理及应用开发技术.北京航空航天大学出版社2002.4
[6]吴晓刚,邢学刚,胡冰山,王瑛,王旭东.基于DSP无级变速箱控制单元的输入信号模拟.哈尔滨理工大学学报.2005年04期
[7]江发潮.汽车AMT电控单元虚拟试验系统的研究.中国农业大学博士学位论文.2003年
[8]温明.现代汽车中的电控技术.汽车技术.1995年2期
[9]牛洪涛.印制电路板的可靠性设计.电子制作.1998年01期
[10]葛安林.车辆自动变速理论与设计.机械工业出版社.1993.5
[11]陈德阳.自动变速器试验台研究.吉林大学硕士学位论文.2003
[12]蔡伟义,李贵炎.自动变速器试验台的研制.客车技术与研究.2003年6期
[13]于海生.CAN总线工业测控网络系统的设计与实现.仪器仪表学报.2001年01期
[14]阳宪惠.现场总线技术及其应用.北京清华大学出版社.1999
[15]dsPIC30F系列参考手册.Microchip Technology Inc.2005