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The Vehicle Control Unit (VCU) of new energy vehicles is the core control component, and the VCU control technology directly impacts the vehicle's performance, safety, and efficiency. The VCU HIL (Hardware-in-the-Loop) simulation testing system performs excitation tests, functional tests, fault reproduction, and extreme condition testing on the tested components, assisting developers in comprehensive and in-depth analysis and verification, ensuring the reliability of the component's functionality.

VCARSYSTEM's Solution

The new energy VCU testing solution provided by VCARSYSTEM focuses on the functional testing and verification of the Vehicle Control Unit (VCU). With its efficient and comprehensive design, the system precisely meets all the requirements of the VCU testing phase. Additionally, the system can be expanded into a four-electric HIL system, enabling coordinated testing of the VCU, Battery Management System (BMS), Motor Controller Unit (MCU), and Fuel Cell Controller (FCU).

HIL SYSTEM

VCARSYSTEM offers Hardware-in-the-Loop (HIL) testing solutions that cover the entire scope of automotive electronics, including modules for new energy powertrain systems (BMS/VCU/MCU), automotive driving systems (ACC/LKA/AEB, etc.), chassis electronic control systems (EPS/ESP/SBW/EPB/EHB/EMB), traditional powertrain systems (EMS/TCU), as well as body electronics and intelligent cockpits. It provides comprehensive HIL testing services to help customers accelerate product launch timelines.

VCAR EM

VCAR EM, developed by VCARSYSTEM for HIL platforms, is an engineering configuration tool that enables comprehensive HIL project setup. The software facilitates GPIO signal configuration, bus communication configuration for CAN/CAN FD, LIN, Ethernet, board hardware configuration, simulation model import, signal mapping, real-time host multi-task allocation and management, and project compilation. It also supports multi-task distribution management and multi-device daisy-chaining configuration, meeting diverse testing scenario requirements.

WORKFLOW

ADVANTAGES

Independently Developed Multi-Functional Board System

Independently develop two core types of boards: one integrates voltage, digital, and PWM signal acquisition functions, and the other is a high-channel communication board supporting CAN, LIN, and FlexRay protocols.

High Integration and Portability

The hardware features high integration and a lightweight design, facilitating easy mobility and simple operation while being adaptable to in-vehicle and various application scenarios.

Rich Configurable Options

Offer a variety of configuration options to meet customized needs, while balancing operational efficiency and cost-effectiveness.

Software License Sharing and Automatic Mapping Configuration

Three types of software—engineering configuration, test management, and automated testing—share a single license to support multi-user access. The mapping between hardware board signals, bus signals, and I/O interface models can be configured automatically.

License-Free Secondary Development and Automatic File Generation

Enable secondary development without the need for an additional license, supporting simultaneous use of physical models across multiple computers. DBC/LDF files and hardware interface definition files can be automatically generated via scripts, with the interface module supporting Override functionality.

Simulink Compatibility and Customized Development Support

Support the import and hierarchical viewing of Simulink physical models without requiring an extra Simulink license. The test management software allows customization of special controls and supports tailored development.

Convenient Fault Injection Functionality

Realize fault injection through variable binding on the fault injection board, eliminating the need for additional fault injection software.

Built-in Measurement and Calibration Library

Provide a built-in measurement and calibration library for controller diagnostics, without the requirement to purchase additional software such as INCA or CANAPE.

FUNCTIONS

Vehicle-Level Functional Testing

Testing of vehicle power on/off, torque, and energy management functions.

Extreme Condition Simulation Testing

Simulating various extreme conditions to perform functional testing of the Vehicle Control Unit (VCU).

Fault Diagnosis Testing

Performing fault injection to execute fault diagnosis tests on the Vehicle Control Unit (VCU).

Vehicle Simulation Models

Building accessible vehicle simulation models for users, supporting precise simulation of component performance by modifying model parameters.

Multi-Platform Support

Supporting various industry-standard simulation model design software platforms, including Matlab/Simulink, CarSim, etc.

IO Interface Testing

Verifying the proper functioning of the controller’s input and output features.

CAN Communication Function Testing

Verifying whether the system adopts different control behaviors under both normal and fault CAN communication scenarios.

Diagnostic Function Testing

Assessing the system’s ability to accurately detect faults in I/O or bus signals and respond accordingly.

Automation Testing

Executing automated testing processes and generating test reports.

CAN Bus Interface and Node Simulation Testing

CAN communication nodes can send messages at specified baud rates (125K baud, 250K baud, 500K baud), receive messages from virtual nodes at the same baud rate, and correctly parse the messages based on the DBC file.

ASSOCIATED PRODUCTS

HIL SYSTEM

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VCAR EA

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VCAR DAS

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VCAR EM

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To address the growing complexity of R&D requirements, we will tailor solutions to your specifications and offer expert consulting and engineering services.

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