Fault Insertions into Hardware-in-the-Loop Simulation
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Date
2020-05
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The Ohio State University
Abstract
The Ohio State EcoCAR Mobility challenge is an intercollegiate team that designs, builds, and tests a hybrid electric vehicle. One of the main goals of this team is to build a hybrid supervisory controls strategy that tests the potential failure mechanisms derived from fault analysis. Currently, Automotive companies are focused on integrating model-based designs enabling simulations for low-cost, rapid experimentation that assess a vehicle's performance. Model-based designs allow engineers to simulate specific tests within controlled environmental conditions. Through the use of model-based design, engineers can test vehicle and component faults inside a simulation model to assess how the vehicle behaves during various failures without incurring the cost of destructive testing.
This thesis, in partner with the EcoCAR Mobility Challenge, aims to incorporate modern industrial fault diagnostics into a hardware-in-the-loop (HIL) simulation and analyze the performance of the model-based design. Fault Tree Analysis (FTA) and Failure Mode and Effect Analysis (FMEA) were used to develop the necessary requirements for the vehicle system. Different faults were intended to be tested for each major component, including, but not limited to, the energy storage system (ESS), rear electric motor, belted alternator starter, DC-DC converter, and the multiplexed vehicle electrical center. The ESS was the only component demonstrated as an example for integrating the fault insertion method. The research details how a standard method was constructed for developing and inserting faults in the HIL test environment. The process is used for testing and designing the control algorithm for a hybrid supervisor controller.