Accurate model based hardware-in-the-loop test for a windscreen wiper system

Hardware-in-the-loop (HIL) simulations have long been used to test electronic control units (ECUs) and software in car manufacturers. It provides an effective platform to the rapid development process of the ECU control algorithms and accommodates the added complexity of the plant under control. Accurate Model based HIL simulation (AMHIL) is considered as a most efficient and cost effective way for exploration of new designs and development of new products, particularly in calibration and parameterization of vehicle stability controllers. The work presented in the paper is to develop a mathematical model of a windscreen wiper system for the purpose of conducting HIL vehicle test and eventually to replace the real component with the model for cost cutting and improved test efficiency. The model is developed based on the electro-mechanical engineering principles. Matlab/Simulink was used as a platform for simulating the mathematical model, in which the real-time code (C language) of the model is complied via Real-time Workshop. dSPACE HIL simulator is adopted as a real-time platform for the HIL tests to the Body Control Module (BCM). The mathematical model of the windscreen system is firstly verified in real-time in line with the real components, wherein varied operational conditions are applied. A real value single population Genetic Algorithm (GA) is adopted to optimize the model parameters with the performance criteria for minimizing the errors between the model simulated swing angles of both cranks and their corresponding swing angels measured from the real wiper system in real time. With the AMHIL, control algorithms embedded in the BCM can be verified in a full scope of the operational ranges. With the ability of adjusting the model parameters to represent different designs of the windscreen wiper systems (e.g. geometric design of the linkage system), AMHIL can verify the control strategy BCM before the real prototype is built, not only in terms of functional tests, but also in terms of reliability and robustness, which can accordingly accelerate production process