System Propulsion Hardware-in-the-Loop for Fuel Cell Vehicles

The automotive industry is becoming increasingly complex with the integration of advanced technologies such as electric vehicles, fuel cell vehicles, and autonomous driving functions. To ensure that these systems operate correctly and safely, rigorous and accurate testing is essential throughout all stages of development. Hardware-in-the-Loop (HIL) technology plays a crucial role in meeting this demand by providing an effective real-time method for testing and validating control systems. In the automotive context, vehicle control systems, such as engine control units or propulsion systems, are integrated with simulated models of the rest of the vehicle and its operational environment. This approach allows for testing and validating control systems in a safe and controlled environment, reducing the need for expensive and potentially hazardous initial physical tests. This thesis, developed in collaboration with Kineton, an automotive consultancy based in Turin, documents the implementation of a Hardware-in-the-Loop solution for the propulsion system of fuel cell vehicles, focusing on a project led by Stellantis. It provides an explanation of how the HIL system is set up and details the operational framework. The study delves into the development of a subsystem model within the complex architecture of the fuel cell system, specifically, a Simulink model of the hydrogen tank. This model is crucial for analyzing the dynamics and operational characteristics of hydrogen storage in fuel cell vehicles and has been tested and validated as part of the larger fuel cell model. To ensure accuracy and reliability, the study briefly examines how the model's outputs compare to real-world data. This comparison is achieved through the analysis of real signals obtained from in-vehicle testing, focusing on communication between the Hydrogen Power Unit (HPU) and critical components, such as the Hydrogen Control Module (HCM) and the Electric Vehicle System Management (EVSM). By examining these aspects, the research aims to demonstrate how HIL technology can improve the effectiveness and efficiency of the development process while ensuring the safety and reliability of innovative propulsion systems in automotive applications.