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To improve product quality and stability, complete system testing is one of the most critical processes. With the external high-speed communication module of the hardware circuit simulation system, the upper control system can quickly connect the controller under test and HiL through RS-485 communication, including controller setting, environment setting (motor and load, etc.), test process planning, The design of test scenarios, etc., can be automated, greatly reducing test time and cost, and improving test coverage and product quality.

The feature of real-time simulation of hardware in the loop system can directly construct a digital clone of the physical system. Take a crane as an example (similar to the dynamics of a single pendulum), such as motor and drive capacity, crane weight, gearbox reduction ratio, rope length, hoisting the weight of the hanging cargo, etc., can be completed through modeling, and then the feasibility of the control method and the optimization of parameters are verified according to this virtual system. After adjusting the HiL, directly input the adjusted controller to the real system for final performance "confirmation". Since the process of design and adjustment is completed in the hardware in the loop system, there is no need for large electricity, no wiring, and no actual machine, which can speed up performance adjustment, and completely avoid risks from tests in the early stage of development., this is the most common and practical application of digital Twin.

Just like electric vehicles, the real-time simulation of the whole vehicle dynamics of electric vehicles also includes vehicle dynamics and road conditions, motor simulation, and motor drive. The only difference is that the modeling of the locomotive and road conditions is changed to the simulation software BikeSim. In this way, the real-time simulation verification platform can be quickly converted from an electric vehicle to an electric vehicle power system verification platform (four wheels to two wheels). It is only necessary to change the relevant parameters in the HiL to the configuration suitable for the use of the electric vehicle, and match it with the electric vehicle. Appropriate drive controller, you can start to verify the control performance and vehicle dynamics of the electric vehicle drive controller

Unlike general simulation software that needs to set parameters before starting the simulation, HiL can instantly modify all system parameters online, so it can simulate changes in parameters between system operations. The most practical example is the case when the parameters of the motor are changed due to the temperature rise, which in turn causes the control effect to decrease. In this case, the customer continuously increased the rotor resistance of the induction motor during operation to simulate temperature rise. It can be clearly seen that the deviation of the magnetic field orientation caused by the change of the rotor resistance reduces the control efficiency (current increase, Speed control accuracy drops).

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