TBOX offline detection system and method

Abstract

The invention discloses a TBOX offline detection system, and relates to the technical field of offline detection. The feedback states of the five groups of indicator lamps are controlled through an ECU, namely, a light 3 is lightened after binding succeeds, a light 5 is lightened after remote shutdown, a light t1 is lightened after first-stage vehicle locking and 2V is displayed by a universal meter, and a light t1 and a light t2 are lightened after second-stage vehicle locking and 0V is displayed; the 279 ECU simulates a vehicle control unit, virtual vehicle number binding and unbinding are input through the cloud platform, and a relay is controlled to switch a power supply. When a vehicle is searched, the buzzer responds, and the rack integrates all the modules to realize physical connection and operation. The detection includes connection initialization, function detection, fault simulation and data storage, and efficiency and accuracy are improved. According to the invention, the detection efficiency is improved through the fast-plug wire harness and an automatic instruction, and the time consumed by a single machine is shortened to 15 minutes or less; errors are reduced through voltage simulation and acousto-optic feedback, and the fault omission ratio is reduced; the real-time evidence storage of the cloud platform ensures the data traceability, supports multi-dimensional retrieval and report generation, solves the problems of low efficiency, large error and difficult traceability of the traditional scheme, and improves the detection reliability and standardization level.

Description

Technical Field

[0001] The present invention relates to the technical field of off-line detection, and in particular to a TBOX off-line detection system and method. Background Art

[0002] With the rapid development of intelligent connected vehicle technology, TBOX (remote vehicle terminal) is a core component for realizing remote vehicle monitoring and data exchange. Its functional stability and reliability directly affect the intelligence level of the entire vehicle. However, the existing TBOX offline inspection technology faces multiple challenges: traditional inspection benches rely on manual wiring harness connection, which is cumbersome and prone to inspection failure due to mis-insertion; when simulating vehicle controller instructions, manual operation cannot accurately control signal timing, making it difficult to reproduce communication scenarios under complex working conditions; status feedback relies on manual observation of indicator lights and reading of instrument data, which is inefficient and prone to errors due to subjective judgment. In addition, inspection data is mostly in the form of paper records or local storage, lacking real-time traceability and analysis capabilities, making it difficult to meet the high requirements of automotive-grade product quality control.

[0003] At the hardware collaboration level, traditional testing solutions lack integrated automated control modules. For example, relays switching power on and off respond slowly, failing to simulate transient power supply changes in a real vehicle. CAN bus communication testing can only complete basic signal transmission tests and lacks fault injection capabilities, making it difficult to verify the TBOX's fault-tolerance mechanisms in bus anomalies (such as short circuits and open circuits). At the software level, the testing process relies on manual orchestration, and operational differences between different testers can easily lead to inconsistent results. Furthermore, the lack of cloud platform interaction prevents remote command issuance and real-time synchronization of test data, limiting the efficiency of large-scale production line testing.

[0004] To address these issues, existing technologies urgently need a testing system that integrates automated hardware, intelligent software, and precise feedback mechanisms to overcome the technical bottlenecks of low efficiency, large errors, and incomplete functional verification in traditional solutions. By building a modular hardware architecture, standardized testing processes, and a digital data management system, intelligent upgrades to TBOX end-of-line testing will become a key technological breakthrough in promoting the industrialization of core components for smart cars. Summary of the Invention

[0005] The present invention proposes a TBOX offline detection system and method to solve the problems mentioned in the above-mentioned prior art.

[0006] In order to achieve the above object, the present invention adopts the following technical solution: a TBOX offline detection system, comprising:

[0007] The power module consists of a 24V constant-voltage power supply, a TBOX, and a 279ECU. The wiring harness connected to the TBOX uses a magnetic quick-plug structure, and the quick-plug structure requires a laser-marked surface. The wiring harness supports ACC ignition and remote power on / off functions. By default, it provides a stable 24V voltage to the TBOX, compatible with the TBOX's wide input requirements, ensuring a stable power connection during testing.

[0008] Signal control module: Set up 5 groups of indicator lights, light1-light5, and control status feedback through 279ECU: After the inspector logs in to the Zhongke Cloud Platform to complete the TBOX binding, the ECU lights up light3; when the unbinding is completed, the ECU turns off light3 and lights up light4; after sending a remote shutdown command, light5 is always on, and after sending a power-on command, light5 turns off; when sending a first-level lock command, light1 lights up and the multimeter displays 2V, and when sending a first-level unlock command, light1 turns off and the multimeter displays 5V; when sending a second-level lock command, light1 and light2 light up and the multimeter displays 0V, and when sending a second-level unlock command, both lights turn off and the multimeter displays 5V, realizing real-time status feedback;

[0009] Vehicle controller simulation module: uses 279ECU to simulate the normally closed relay built into the vehicle controller. When receiving the vehicle lock command, the relay switches to the open state, simulating the vehicle power cut-off logic. It supports communication with TBOX via the CAN bus to verify TBOX functions. During the communication process, it can send binding, unbinding, remote power on / off, and first and second level locking commands. The command transmission is stable and there is no delay or lag.

[0010] Cloud platform interaction module: Inspectors log in to the Zhongke cloud platform through a mobile app and enter a virtual vehicle number to bind or unbind the TBOX from the vehicle controller. The cloud platform is responsible for issuing commands to the TBOX and receiving status feedback, ensuring the accuracy of command transmission and supporting real-time monitoring of the TBOX status during the inspection process.

[0011] Status feedback module: This module includes a buzzer and a multimeter. When a vehicle search command is sent, the buzzer immediately responds with a sound and the light 5 flashes synchronously, providing an audible and visual alarm. The multimeter monitors voltage changes in real time to verify that the voltage response of the TBOX to different commands meets expectations. For example, the voltage is stabilized at 2V±0.1V during level one locking and 0V±0.05V during level two locking.

[0012] Furthermore, it also includes:

[0013] The test bench module includes a support frame, indicator lights, push-button switches, power sockets, and wiring harness interfaces, providing physical support and an operating interface for the test system. TBOX positioning slots are provided on the table to ensure accurate placement of the TBOX and facilitate wiring harness connection. The operation panel layout is ergonomic, making it easy for testers to send commands and observe status.

[0014] In the signal control module, the 2V voltage displayed by the multimeter when the vehicle is locked at the first level is realized through a resistor divider network. The voltage divider resistors include R1, 1kΩ and R2, 120Ω connected in series. The formula is: The output voltage is calculated as In actual testing, the resistance parameters are adjusted to ensure that the multimeter displays 2V±0.1V, thereby accurately simulating the voltage requirements in the first-level locking state.

[0015] Furthermore, the cloud platform interaction module supports user operation management, and users with different permissions perform different inspection operations; the inspection personnel account has basic permissions to bind, unbind, and send inspection instructions, and the administrator account configures and manages the inspection process and virtual vehicle license plate rules. All operation records are stored in the cloud, and support query and tracing by user and time dimensions.

[0016] Furthermore, the wiring harness interface of the test bench module adopts a fool-proof design, and the CANH, CANL, 24+ power supply, and GND interfaces all have independent physical labels; the wiring harness storage area is set on the side of the test bench, and a magnetic card is used to fix the commonly used wiring harness, which is convenient for access and prevents the wiring harness from being entangled and knotted.

[0017] Furthermore, the normally closed relay in the vehicle controller simulation module adopts a stable model to ensure that the TBOX power supply can be cut off when the vehicle lock command is sent; the relay is in the closed state by default, ensuring the stability of the TBOX when it is powered normally.

[0018] Furthermore, the buzzer in the status feedback module adopts a high-decibel model to ensure that the detection personnel can perceive the response to the vehicle search command in the workshop environment; light5 uses a high-brightness LED light to facilitate observation of the status in a dimly lit environment.

[0019] Furthermore, the magnetic quick-plug wiring harness of the power module is adaptable to the humid and dusty environment of the workshop; the wiring harness label adopts laser marking technology.

[0020] A method for applying the TBOX offline detection system includes:

[0021] Device connection and initialization: Place the TBOX in the test bench positioning slot and quickly connect the 24V power supply, 279ECU, and CAN bus interface via the magnetic quick-plug wiring harness. The inspector logs in to the Zhongke Cloud Platform via the mobile app, enters the virtual vehicle number, and clicks the bind button. The 279ECU sends the binding command and observes whether the light3 lights up. If so, the binding is confirmed to be successful and the inspection process begins.

[0022] Remote power on / off test: Send a remote power off command on the cloud platform and observe whether Light 5 lights up. At the same time, use a multimeter to check whether the voltage at the TBOX power supply drops to near 0V and record the power off response time. Wait 10 seconds, then send a remote power on command to observe whether Light 5 goes off and whether the voltage returns to 24V. Record the power on response time.

[0023] Level 1 and 2 unlocking test: Send the level 1 lock command, observe whether light 1 lights up and whether the multimeter displays 2V±0.1V, confirming that the level 1 lock function is normal; send the level 1 unlock command, observe whether light 1 goes out and whether the multimeter displays 5V±0.2V, confirming that the level 1 unlock function is normal; send the level 2 lock command, observe whether light 1 and light 2 light up at the same time and whether the multimeter displays 0V, confirming that the level 2 lock function is normal; send the level 2 unlock command, observe whether both lights go out and whether the multimeter displays 5V, confirming that the level 2 unlock function is normal;

[0024] Car search function test: Send a car search command to test whether the buzzer responds within 0.5 seconds. At the same time, observe whether light5 flashes synchronously, the flashing frequency is 1Hz, and the duration is 10 seconds. This verifies the accuracy of the sound and light feedback of the car search function.

[0025] Unbinding and resetting: After the test is completed, click the unbinding button on the cloud platform and observe whether light 3 is off and light 4 is on to confirm that the TBOX is disconnected from the cloud. Disconnect the magnetic quick-connect wiring harness, remove the TBOX from the stand positioning slot and return it to its original position. Rearrange the test equipment and wiring harness.

[0026] Furthermore, during the remote power on / off detection step, if the response time exceeds the standard once in three consecutive tests, it is determined that there is an abnormality in the TBOX power management module and troubleshooting is required. During the detection process, the voltage waveform is synchronously recorded, and waveform analysis is used to determine whether the power connection is stable and whether there are any momentary interruptions or surges, thereby ensuring the stability of the TBOX power-related functions.

[0027] Furthermore, a computer program is stored, which, when executed by the processor, can realize real-time recording of the indicator light state change time, voltage value, instruction sending and response time data during the detection process; the data is stored in a table form, including detection time, virtual vehicle number, TBOX model, and result information of each detection item, and supports filtering and querying according to detection time range and TBOX model conditions, providing data support for detection quality analysis and traceability.

[0028] Compared with the existing technology, the beneficial effects of the present invention are:

[0029] The system utilizes a magnetic quick-connect wiring harness design, enabling the TBOX to connect to the test bench in seconds. This eliminates the time-consuming and risky manual plug-in and unplugging process, reducing the connection time for a single device from two minutes to less than one second. The 279ECU simulates the functions of a vehicle controller, automatically issuing remote commands such as power on / off and locking the vehicle. Command transmission latency is less than 100 milliseconds, resulting in 100% automation of the testing process. This reduces the time required for a single test from 30 minutes in traditional solutions to less than 15 minutes, significantly improving production line throughput.

[0030] In terms of detection accuracy, the system uses a resistor divider network and a high-precision multimeter to precisely simulate and measure the locking voltage. The voltage is stabilized at 2V±0.1V during level one locking, and the voltage error is controlled within 0V±0.05V during level two locking, reducing the error by over 90% compared to traditional manual measurement. The linkage between the indicator light and buzzer reduces the vehicle search function's response time to under 0.5 seconds. The real-time audio and visual feedback ensures that inspectors can quickly identify the function's status. Furthermore, the system supports CAN bus fault simulation, injecting six types of faults, such as short circuits and open circuits, via solid-state relays. The TBOX must trigger the corresponding fault code and provide feedback through the indicator light within 100 milliseconds, effectively improving the coverage and accuracy of fault detection.

[0031] Improved data management capabilities are another core advantage of this patent. Voltage data, CAN messages, operation timestamps, and other information generated during the test are encrypted and stored in real time on the cloud platform. This supports multi-dimensional retrieval based on virtual vehicle numbers, test times, and other factors, and historical data is retained for at least five years. The application of blockchain technology ensures that data cannot be tampered with, meeting the traceability requirements of international standards such as ISO17025 and addressing the vulnerability of traditional paper records to loss and tampering. The system also supports the automatic generation of multilingual test reports, including test results, waveform analysis, and qualification determinations, further enhancing the standardization and international compatibility of the test process.

[0032] In summary, this application has built an efficient and reliable TBOX end-of-line testing solution through the triple innovations of hardware automation, testing standardization, and data intelligence. This solution not only significantly reduces labor costs and operational errors, but also improves quality control through full-process digital management. It provides key technical support for the large-scale mass production of core components for intelligent connected vehicles, and has significant industrial application value and market competitiveness. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a schematic block diagram of a TBOX offline detection system proposed by the present invention;

[0034] Figure 2 This is a schematic block diagram of a TBOX offline detection method proposed in the present invention;

[0035] Figure 3 This is a schematic diagram of the time distribution of the detection process of a TBOX offline detection method proposed in the present invention;

[0036] Figure 4 This is a schematic diagram of the voltage change response curve of a TBOX offline detection method proposed in the present invention. DETAILED DESCRIPTION

[0037] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0038] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like to indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0039] In addition, the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the said features. In the description of the present invention, the meaning of "multiple" is two or more, unless otherwise clearly and specifically defined. In addition, the terms "installed", "connected" and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be a connection between the two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances. The present invention will be further described in detail below with reference to the accompanying drawings.

[0040] Reference Figures 1 to 4 : A specific implementation method of a TBOX offline detection system and method.

[0041] System hardware composition and technical implementation

[0042] Power module:

[0043] The power module provides stable power for the entire detection system. Its core is a 24V constant-voltage switching power supply with an output power of ≥200W. It features a wide input range (20V-28V) to accommodate the power requirements of different TBOX models. The power output incorporates an integrated overcurrent protection circuit with a trip threshold set to 15A. If an abnormality such as a short circuit occurs in the TBOX, power is cut off within 0.1 seconds to prevent damage. The wiring harness connecting to the TBOX utilizes a magnetic, quick-connect structure and is made of TE Connectivity's DEUTSCHDT series waterproof wiring harness. It boasts an IP67 rating, offering protection against dust and liquid intrusion in the workplace, and a plug-in / plug-out lifespan tested to ≥100,000 cycles. The wiring harness is laser-marked with symbols such as "24+Power," "GND," "CAN_H," and "CAN_L." The font height is 2mm, and the material is abrasion-resistant, ensuring legibility even after prolonged alcohol wiping. An NTAG213 RFID tag with a storage capacity of 888 bytes is implanted inside the wiring harness. It can record information such as TBOX model, power supply protocol (such as 24V±10%), and detection script index. Contactless identification is achieved through the ImpinjR420 reader / writer, with a reading distance of ≤10cm and a response time of ≤0.1 second. Power supply scheme matching can be completed within 0.5 seconds, completely avoiding the problem of manual misplugging and misconnection.

[0044] Power module key parameters and function chart

[0045]

[0046]

[0047] Chart Explanation

[0048] Power supply and protection: The 24V constant voltage power supply is compatible with TBOX, and the wide input range is compatible with different scenarios. The overcurrent protection responds quickly to protect equipment safety.

[0049] Harness features: Magnetic quick-connect + IP67 protection, adaptable to complex workshop environments, wear-resistant markings and long plug-in life to ensure long-term stable connection.

[0050] Intelligent identification: RFID tags store device parameters, readers and writers quickly identify devices without contact, and complete power supply matching within 0.5 seconds, eliminating the risk of manual wiring errors and improving operation and maintenance efficiency.

[0051] Signal control module:

[0052] The system's nerve center, it simulates CAN bus signals using VectorCANoe 11.0 software, with a set baud rate of 500kbps and strict adherence to the ISO15765-2 diagnostic protocol. It generates standard frames (such as the 0x7DF diagnostic request frame) and extended frames (such as the 0x18FF5000 power data frame), maintaining signal amplitude error within 1.5% and frequency error within 0.5%, ensuring high consistency between the simulated signal and the actual vehicle environment. The indicator light cluster consists of five WS2812B RGB LEDs, precisely controlled by the TM1814 driver chip. Initially, lights 1 through 5 are all off. When the inspector logs into the Zhongke Cloud Platform to complete the TBOX binding, the ECU outputs a high-level signal, and light 3 (blue) remains on with a 100% PWM duty cycle. Upon unbinding, light 3 turns off, and light 4 (green) turns on. Upon a remote shutdown command, light 5 (red) remains on, and the normally closed relay opens. A multimeter detects a voltage of ≤0.5V at the TBOX power supply terminal. In the first-level locking mode, light 1 (red) turns on, and the multimeter displays 2V through the resistor divider network (R1 = 10kΩ, R2 = 20kΩ). The calculation formula is \(V = \frac{R_2}{R_1+R_2}\times24V = \frac{20kΩ}{30kΩ}\times24V = 16V\). After the attenuation resistor (R3 = 14kΩ), it is reduced to 2V±0.1V. In the second-level locking mode, light 1 and light 2 (green) are mixed to yellow with a PWM duty cycle of 7:3. At this time, the relay completely cuts off the power supply, and the multimeter displays 0V.

[0053] Key parameters and function chart of signal control module:

[0054]

[0055] Signal accuracy: By clarifying the CAN bus simulation parameters (baud rate, protocol, error), the signal is guaranteed to be highly consistent with the actual vehicle environment, providing a reliable test benchmark for the detection system and reducing test errors caused by signal deviation.

[0056] Status visualization: The multi-state lighting effects of the indicator lights correspond to the system processes (login, unbinding, shutdown, and locking the car), converting abstract signal states into intuitive lights, making it easier for inspection personnel to quickly identify the system operation stage and improve debugging and troubleshooting efficiency.

[0057] Scenario Reproducibility: In the vehicle locking logic, the resistor voltage divider formula and mixed light design accurately reproduce the voltage changes and lighting effects of the first and second level locking, fully simulating the entire vehicle locking scenario. This helps verify the compatibility and reliability of TBOX and related systems under vehicle locking conditions, ensuring that the product is adaptable to real-world vehicle usage environments.

[0058] Vehicle controller simulation module:

[0059] The 279ECU is built around the Infineon AURIXTC275 chip, running at 200MHz and employing a triple-core Cortex-M7 architecture. It runs the AUTOSAR real-time operating system and integrates a CAN controller and a 16-bit ADC (sampling rate 10kHz), accurately simulating the communication logic and control commands of a vehicle controller. The module features a built-in normally closed relay (model G5V-1-DC24V). By default, the contacts are closed, providing a stable 24V power supply to the TBOX. Upon receiving a vehicle lock command, the relay coil energizes, the contacts open, and the power is cut off, simulating a remote vehicle shutdown scenario. The power-off response time is ≤50ms. After unlocking, the contacts reset, and the power-on response time is ≤80ms. The module supports operations such as reading TBOX fault codes by sending the "1902" command and reading the software version number by sending the "22F186" command. Communication latency is ≤50ms, and signal accuracy is ≥99.5%, ensuring stable and reliable communication with the TBOX.

[0060] Vehicle controller simulation module parameters and function table:

[0061]

[0062]

[0063] Technical transparency: The core parameters of the chip, system, and peripherals (relays, ADC) are clearly presented, making the technical architecture of the vehicle controller simulation module clear at a glance. This allows R&D personnel to quickly understand the module's capability boundaries and provide a reference for system integration and function expansion.

[0064] Scenario verification support: By using indicators such as the relay's "power off / power on response time" and "communication instructions and delays," the system accurately matches real-world scenario requirements such as "remote power on / off" and "fault code reading" for the entire vehicle, providing a highly simulated environment for TBOX testing, reducing reliance on actual vehicle testing, and improving test efficiency and coverage.

[0065] Reliability quantification: Quantitative indicators such as communication accuracy (≥99.5%) and response time (≤50ms / 80ms) intuitively reflect the stability and accuracy of the module's simulation of the vehicle controller, helping testers quickly determine whether functions such as communication interaction and power control meet standards, accelerating problem location and iterative optimization.

[0066] The cloud platform interaction module enables intelligent and remote management of the inspection process. Inspectors log in to the Zhongke Cloud Platform via a mobile app developed based on ReactNative and enter the virtual vehicle license plate number "HMYJ18E00001" to perform operations. This virtual vehicle license plate number uses a fixed encoding rule: the first four digits "HMYJ" are the company code, and the last 13 digits "18E00001" contain a timestamp and Luhn checksum to ensure uniqueness and anti-counterfeiting. Commands are transmitted via the MQTT protocol (QoS = 1) with a latency of ≤100ms, enabling remote control of functions such as binding, unbinding, remote power on / off, and locking the vehicle. Inspection logs are stored in real time on the cloud, including command time (accurate to milliseconds), voltage data (0.01mV resolution), CAN message IDs, and data segments (such as the binding confirmation frame "0x7E80200"). Data is encrypted and stored according to ISO27001 standards and supports retrieval based on the "vehicle number + time + fault code" combination. Historical data is retained for ≥5 years, meeting industrial-grade data traceability requirements.

[0067] Status feedback module:

[0068] The system performs the crucial functions of visualizing test results and providing fault alarms. The vehicle-finding function is achieved through the interaction of an FMQ-12F buzzer and the Light5. The buzzer has a volume of 85dB±3dB and a frequency of 2kHz. Upon receiving a vehicle-finding command, it responds within 0.3 seconds, using a "long beep for 2 seconds followed by a 1-second pause" pattern repeated three times. Simultaneously, the Light5 flashes at a 1Hz frequency with a 50% duty cycle, ensuring clear perception even in noisy workshop environments. Voltage detection utilizes a Fluke high-precision multimeter with a resolution of 0.01mV, enabling real-time monitoring of the TBOX voltage changes under different commands. For example, a display of 5V±0.2V is displayed for level one unlocking, returning to 5V±0.2V for level two unlocking. In addition, the module uses an 8-channel solid-state relay array (G3VM-352C, switching speed ≤ 5ms) to simulate six types of CAN bus faults, including CAN_L short circuit to ground, CAN_H short circuit to power, and CAN_H open circuit. After fault injection, the TBOX must trigger the corresponding fault code within 100ms (such as CAN_H open circuit triggering P0562). The light3 flashes at a frequency of 0.5 times / second, and the multimeter simultaneously monitors voltage jumps to achieve precise fault location and response testing.

[0069] Function parameter table of status feedback module:

[0070]

[0071] Functional Clarity: The three core functions of "vehicle search, voltage detection, and fault simulation" are broken down. Through parameters (such as buzzer volume and multimeter resolution) and logic (such as fault code triggering requirements), the action path of the status feedback module is made clear at a glance, facilitating a quick understanding of how the module supports TBOX detection.

[0072] Precision testing: Quantitative indicators (such as 50% duty cycle and 100ms fault response) clarify test standards, helping testers accurately reproduce scenarios (such as vehicle search command triggering) and verify functions (such as TBOX fault code output), reducing manual operation errors and improving test consistency.

[0073] Comprehensive scenario coverage: From "human-machine interaction prompts" to "electrical signal monitoring" to "fault injection verification," it comprehensively covers the diverse requirements of TBOX testing. Charts can quickly determine whether the module is suitable for the test scenario, helping to build a complete and efficient testing process and accelerate problem discovery and resolution.

[0074] Bench module:

[0075] It provides a solid physical support and human-machine interface for the detection system. The main structure is made of European standard 4080 industrial aluminum profile, the surface is conductively oxidized, the load-bearing capacity is ≥300kg, the table size is 600mm×400mm, and a 7-inch touch screen is integrated on the left (resolution 1024×600, supports glove operation), and the right side is equipped with a power socket, DB9 pin-type CAN interface and indicator light group. A TBOX positioning slot is set in the center of the table with an accuracy of ±0.5mm, and a pressure sensor matrix (accuracy 0.1g / cm 2 ) If the TBOX placement is detected to be offset by more than 3mm, an audible and visual alarm is immediately triggered to ensure accurate device connection. The tabletop height is electrically adjustable from 750mm to 1050mm with an accuracy of ±1mm. The operation panel tilt can be adjusted from 15° to 45° to accommodate the operating habits of inspectors of different heights. The right side is equipped with a magnetic harness storage drawer with 10 commonly used harnesses. RFID tags are used to identify the type of harness. If it is not returned after 30 minutes, the app will automatically send a reminder message to keep the table clean and tidy.

[0076] Full process of detection method

[0077] Device connection and initialization:

[0078] At the start of the test, the inspector steadily places the TBOX in the center slot of the test bench. The magnetic quick-connect wiring harness automatically aligns and connects the 24V power supply, CAN bus interface (CAN_H, CAN_L), and GND pins. The entire process requires no manual alignment and takes less than 1 second. The Impinj reader quickly recognizes the RFID tag embedded in the wiring harness, reading the TBOX model (e.g., "TBOX-V2.3") within 0.08 seconds and automatically loading the corresponding test script (passenger car TBOXs comply with ISO standards, and engineering vehicle TBOXes comply with GB / T standards). The inspector then enters the virtual vehicle number "HMYJ18E00001" on the mobile app's main interface and clicks the "Bind" button. The cloud platform generates a 6-digit one-time key (OTP) valid for 5 minutes. Once the input is verified, the 279ECU sends a handshake message "0x7DF00" to the TBOX and waits for the TBOX to respond with a confirmation signal "0x7E800" with a timeout of 1 second. If no response is received within the time limit, the system prompts "Communication link failure". The inspector needs to check whether the wiring harness is firmly connected, re-plug and try binding again; if binding is successful, light3 (blue) is always on, and the touch screen displays "Binding completed, ready for testing". The entire initialization process takes ≤ 2 minutes.

[0079] Remote power on / off detection:

[0080] After the binding is complete, the tester sends a "remote shutdown" command via the mobile app. Upon receiving the command, the 279ECU opens the normally closed relay within 0.1 seconds, and light 5 (red) illuminates simultaneously. A Fluke multimeter is then used to test the voltage at the TBOX power supply terminal. It should drop to ≤0.5V within 1 second. The shutdown response time, T1, is recorded. This test is repeated three times, and the average value should be ≤1 second. After waiting 15 seconds, the "remote power on" command is sent. The relay contacts reset and close, light 5 turns off, and the voltage gradually returns to 24V±0.2V. The power on response time, T2, is recorded. The average power on time is required to be ≤2 seconds, and the difference in voltage stabilization time between the three tests should be ≤5%. This step verifies the TBOX's power management capabilities under remote control, ensuring it accurately responds to power on and off commands. Voltage waveform monitoring (captured using an oscilloscope) is also used to eliminate abnormalities such as power outages and surges, ensuring the reliability of the vehicle's power supply control function.

[0081] Level 1 and 2 unlock detection:

[0082] During the first-level unlocking test, the tester first sends the "first-level lock" command. Within 0.3 seconds after receiving the command, the 279ECU controls light 1 (red) to light up. At the same time, the multimeter displays 2V±0.1V through the resistor voltage divider network. The lock time T3 is recorded, which is required to be ≤0.5 seconds. After maintaining the lock state for 10 seconds, the "first-level unlock" command is sent, light 1 goes out, and the multimeter voltage returns to 5V±0.2V. The unlock time T4 is recorded, which is required to be ≤0.4 seconds. During the second-level unlocking test, the "second-level lock" command is sent, light 1 and light 2 (green) are displayed in mixed yellow. At this time, the relay completely cuts off the power supply, the multimeter displays 0V, and the lock time T5 is recorded, which is required to be ≤0.6 seconds. After 10 seconds, the "second-level unlock" command is sent, both lights go out, the voltage returns to 5V±0.2V, and the unlock time T6 is recorded, which is required to be ≤0.5 seconds. During the entire testing process, the CAN bus load rate must be monitored synchronously, requiring it to be ≤65% for level one locking and ≤50% for level two locking, with no frame loss (frame loss rate ≤0.1%). This verifies the function restriction logic and power control accuracy of the TBOX in different locking states, ensuring that the user authority management function meets the design requirements.

[0083] Car search function detection:

[0084] The inspector clicks the "Find Car" button on the mobile app to send a find car command to TBOX. The system must respond within 0.3 seconds: the FMQ-12F buzzer emits a sound at 85dB±3dB at a frequency of 2kHz, with a beeping pattern of "long beep for 2 seconds followed by a pause for 1 second" repeated three times. Simultaneously, light5 (red) flashes at a frequency of 1Hz with a duty cycle of 50%. The inspector must closely observe the synchronization between the indicator light flashing frequency and the buzzer sound, and use a decibel meter to measure the volume to ensure it is within the standard range. A stopwatch is used to record the time difference from the command being sent to the activation of the sound and light, which should be ≤0.5 seconds. After 10 seconds of continuous testing, the sound and light feedback automatically stops. This step mainly verifies TBOX's ability to respond quickly to receiving the find car command and the reliability of the sound and light alarms, ensuring that users can quickly locate vehicles through this function in actual applications.

[0085] Unbinding and resetting:

[0086] After all test items are completed and the results are qualified, the tester clicks the "Unbind" button on the mobile phone app. The 279ECU sends the unbinding command, light3 (blue) goes out, light4 (green) lights up, and the TBOX is disassociated from the cloud. The entire unbinding process takes ≤1.5 seconds. Then, disconnect the magnetic quick-plug wiring harness, remove the TBOX from the positioning slot, and return it to the designated storage area. The tester organizes the wiring harnesses on the test stand and puts them back into the magnetic storage drawer according to type. The touch screen automatically clears the current test data, and the counter accumulates "+1" to display "Current total number of tests: XXX units." Finally, check whether the various components of the test stand are properly returned to their original positions to ensure that there are no looseness or abnormalities, and prepare for the next test. The entire reset process takes ≤1 minute. Through strict unbinding and reset operations, the status of the test equipment is reset to prevent residual data from affecting subsequent tests. At the same time, the safe disconnection of TBOX from the cloud platform is guaranteed to prevent unauthorized access.

[0087] The above are only preferred specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with this technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solutions and inventive concepts of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. A TBOX offline detection system, characterized in that: include: The power module consists of a 24V constant-voltage power supply, a TBOX, and a 279ECU. The wiring harness connected to the TBOX uses a magnetic quick-plug structure, and the quick-plug structure requires a laser-marked surface. The wiring harness supports ACC ignition and remote power on / off functions. By default, it provides a stable 24V voltage to the TBOX, compatible with the TBOX's wide input requirements, ensuring a stable power connection during testing. Signal control module: Set up 5 groups of indicator lights, light1-light5, and control status feedback through 279ECU: After the inspector logs in to the Zhongke Cloud Platform to complete the TBOX binding, the ECU lights up light3; when the unbinding is completed, the ECU turns off light3 and lights up light4; after sending a remote shutdown command, light5 is always on, and after sending a power-on command, light5 turns off; when sending a first-level lock command, light1 lights up and the multimeter displays 2V, and when sending a first-level unlock command, light1 turns off and the multimeter displays 5V; when sending a second-level lock command, light1 and light2 light up and the multimeter displays 0V, and when sending a second-level unlock command, both lights turn off and the multimeter displays 5V, realizing real-time status feedback; Vehicle controller simulation module: uses 279ECU to simulate the normally closed relay built into the vehicle controller. When receiving the vehicle lock command, the relay switches to the open state, simulating the vehicle power cut-off logic. It supports communication with TBOX via the CAN bus to verify TBOX functions. During the communication process, it can send binding, unbinding, remote power on / off, and first and second level locking commands. The command transmission is stable and there is no delay or lag. Cloud platform interaction module: Inspectors log in to the Zhongke cloud platform through a mobile app and enter a virtual vehicle number to bind or unbind the TBOX from the vehicle controller. The cloud platform is responsible for issuing commands to the TBOX and receiving status feedback, ensuring the accuracy of command transmission and supporting real-time monitoring of the TBOX status during the inspection process. Status feedback module: This module includes a buzzer and a multimeter. When a vehicle search command is sent, the buzzer immediately responds with a sound and the light 5 flashes synchronously, providing an audible and visual alarm. The multimeter monitors voltage changes in real time to verify that the voltage response of the TBOX to different commands meets expectations. For example, the voltage is stabilized at 2V±0.1V during level one locking and 0V±0.05V during level two locking.

2. A TBOX offline detection system according to claim 1, characterized in that: Also includes: Test bench module: including support frame, indicator light, key switch, power socket and wiring harness interface, providing physical support and operation interface for the detection system; The tabletop is equipped with TBOX positioning slots to ensure accurate TBOX placement and facilitate wiring harness connection; the operation panel layout conforms to ergonomics, making it convenient for inspectors to send commands and observe status. In the signal control module, the 2V voltage displayed by the multimeter when the vehicle is locked at the first level is realized through a resistor divider network. The voltage divider resistors include R1, 1kΩ and R2, 120Ω connected in series. The formula is: The output voltage is calculated as In actual testing, the resistance parameters are adjusted to ensure that the multimeter displays 2V±0.1V, thereby accurately simulating the voltage requirements in the first-level locking state.

3. The TBOX offline detection system according to claim 1, characterized in that: The cloud platform interaction module supports user operation management, and users with different permissions perform different inspection operations; the inspection personnel account has basic permissions to bind, unbind, and send inspection instructions, and the administrator account configures and manages the inspection process and virtual vehicle license plate rules. All operation records are stored in the cloud, supporting query and tracing by user and time dimensions.

4. The TBOX offline detection system according to claim 2, characterized in that: The wiring harness interface of the test bench module adopts a fool-proof design, and the CANH, CANL, 24+ power supply, and GND interfaces all have independent physical labels; the wiring harness storage area is set on the side of the test bench, and the commonly used wiring harnesses are fixed with magnetic cards, which is convenient for access and prevents the wiring harnesses from being entangled and knotted.

5. The TBOX offline detection system according to claim 1, characterized in that: The normally closed relay in the vehicle controller simulation module adopts a stable model to ensure that the TBOX power supply can be cut off when the vehicle lock command is sent; the relay is in the closed state by default to ensure the stability of the TBOX when it is powered normally.

6. The TBOX offline detection system according to claim 1, characterized in that: The buzzer in the status feedback module adopts a high-decibel model to ensure that the detection personnel can perceive the response to the vehicle search command in the workshop environment; light5 uses a high-brightness LED light to facilitate observation of the status in a dimly lit environment.

7. The TBOX offline detection system according to claim 1, characterized in that: The magnetic quick-plug wiring harness of the power module is suitable for the humid and dusty environment of the workshop; the wiring harness label adopts laser marking technology.

8. A method for applying the TBOX offline detection system according to any one of claims 1 to 7, characterized in that: include: Device connection and initialization: Place the TBOX in the test bench positioning slot and quickly connect the 24V power supply, 279ECU, and CAN bus interface via the magnetic quick-plug wiring harness. The inspector logs in to the Zhongke Cloud Platform via the mobile app, enters the virtual vehicle number, and clicks the bind button. The 279ECU sends the binding command and observes whether the light3 lights up. If so, the binding is confirmed to be successful and the inspection process begins. Remote power on / off test: Send a remote shutdown command on the cloud platform and observe whether Light5 lights up. At the same time, use a multimeter to check whether the voltage at the TBOX power supply drops to close to 0V and record the shutdown response time. Wait 10 seconds and then send a remote power-on command. Observe whether light 5 goes out and the voltage returns to 24V. Record the power-on response time. Level 1 and 2 unlocking test: Send the level 1 lock command, observe whether light 1 lights up, and whether the multimeter displays 2V±0.1V, confirming that the level 1 lock function is normal; send the level 1 unlock command, observe whether light 1 goes out, and whether the multimeter displays 5V±0.2V, confirming that the level 1 unlock function is normal; send the level 2 lock command, observe whether light 1 and light 2 light up at the same time, and whether the multimeter displays 0V, confirming that the level 2 lock function is normal; Send the second-level unlocking command and observe whether the two lights are off and whether the multimeter displays 5V to confirm that the second-level unlocking function is normal; Car search function test: Send a car search command to test whether the buzzer responds within 0.5 seconds. At the same time, observe whether light5 flashes synchronously, the flashing frequency is 1Hz, and the duration is 10 seconds. This verifies the accuracy of the sound and light feedback of the car search function. Unbinding and resetting: After the test is completed, click the unbinding button on the cloud platform and observe whether light 3 is off and light 4 is on to confirm that the TBOX is disconnected from the cloud. Disconnect the magnetic quick-connect wiring harness, remove the TBOX from the stand positioning slot and return it to its original position. Rearrange the test equipment and wiring harness.

9. A TBOX offline detection method according to claim 8, characterized in that: During the remote power on / off test, if the response time exceeds the standard once in three consecutive tests, it is determined that there is an abnormality in the TBOX power management module and troubleshooting is required. During the test, the voltage waveform is synchronously recorded and analyzed to determine whether the power connection is stable and whether there are any momentary interruptions or surges, thereby ensuring the stability of the TBOX power-related functions.

10. A computer-readable storage medium, characterized in that A computer program is stored, which, when executed by the processor, can realize real-time recording of indicator light status change time, voltage value, instruction sending and response time data during the detection process; the data is stored in a table form, including detection time, virtual vehicle number, TBOX model, and results of each detection item, and supports filtering and querying by detection time range and TBOX model conditions, providing data support for detection quality analysis and traceability.

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