HiL Testing of Automotive Transients in Electric Vehicle 2022-28-0378

In comparison to conventional IC engine vehicles, Electric Vehicles (EV) have a higher number of Electronic Control Units (ECUs). The ECUs are vulnerable to electrical disturbances due to switching of protective devices, passive, and active components, and while charging the battery packs. Electrical disturbances such as power transients, short interruptions in power supply and signal lines, and short circuits are unavoidable and can adversely influence ECU safety in many driving scenarios. Testing and understanding the behavior of ECUs under these conditions can prevent failure of the ECUs. The IS016750-2 and ISO 21780 standards are quality and reliability test standards that describes on how the automotive ECUs should react to electrical disturbances that can occur in the electrical system while driving. The compliance of ECUs to these ISO standards enables safe and stable operation of the EV. The duration of transients that occur in EVs are very short and the ISO standard compliance tests such as pin interruption, momentary drop in voltage, and overvoltage tests make manual simulation and testing non-viable. The RT stand Hardware-in-the-Loop (HIL) simulation rig is an automated system for testing the adherence of ECUs to ISO16750-2/ISO21780 standards. This system supports automated testing and customized test creation for all vehicle ECUs enabling continuous monitoring and automatic report generation thus, reducing human error and improving accuracy. The waveform for the test scenario is fed to the Device Under Test (DUT) and its behavior is analyzed to check for its adherence to the standards. The simulation and testing of various transient phenomena that occur in vehicles are discussed in this paper.