Model-Based Software Development and Testing of a Vehicle Control Unit for an Electric Retrofit Kit

This thesis is based on a retrofit kit project aimed at converting vintage vehicles into electric ones. Specifically, it focuses on the model-based software development of the Vehicle Control Unit (VCU), the kit component responsible for regulating and supervising vehicle operations. In preparation for the work, a comprehensive study of electric vehicles was conducted, covering history, the state of the art, topologies, and key components. Subsequently, the existing VCU algorithm, implemented in LabVIEW®, was thoroughly analyzed to gather requirements and understand specifications. Documentation and schematic representations were produced to map the control logic, by tracking the variables flow and structuring a data dictionary. The core of the work involved porting the LabVIEW-based code into Simulink® environment, eliminating redundant code and fixing inconsistencies in the process. At first, unit test cases were developed and conducted to guarantee one-to-one functional equivalence. Then, the implementation was refined by enhancing functionalities and adding diagnostics. At this point, a modular model of the plant was developed to perform Model-in-the-loop (MIL) simulation and testing. In Simulink, the controller model was configured for code generation and prepared for deployment onto the rapid prototype ECU for Processor-in-the-Loop (PIL) validation of real-time constraints. In preparation for this stage, the technical steps required to flash a sample code onto the provided prototype ECU were reviewed and documented. In this way, the project was set up for future Hardware-in-the-Loop (HIL) testing on the test bench. This experience has been valuable in establishing a structured approach to software development within a professional framework.