Production line end automobile controller simulation test method and system

Abstract

The invention discloses a production line end automobile controller simulation test method and system, and the method comprises the following steps: S1, collecting test requirements, and releasing related design data and test samples; s2, building a test bench, wherein the test bench comprises a simulation test model, a simulation test interface, simulation closed-loop debugging and bench integration debugging; s3, simulating the test case, and converting the test case into an automatic test script; and S4, implementing a simulation test, and forming a test report. According to the invention, the whole life cycle quality assurance process from research and development design to production inspection of the whole vehicle electrical system is perfected, and the method has great practical application value.

Description

Technical Field

[0001] The present invention relates to the technical field of automotive controller testing, and particularly to a method and system for simulating and testing automotive controllers at the production line end. Background Art

[0002] In the production line testing process of automotive controllers, with the increasing intelligence of automobiles and the increasing integration of electrical functions, the traditional end-of-line (EOL) electrical inspection testing has limitations. Due to the single testing method (only reading electrical state information, interfaces, and configurations through diagnostic services) and limited testing scope (lacking an intelligent driving function verification environment, unable to carry out high-efficiency automated scenarios and performance testing for the intelligent cockpit system, and unable to cope with high-efficiency iterative testing for vehicle electrical design changes), it is impossible to achieve effective testing with high coverage at multiple levels of the vehicle electrical system, resulting in missing electrical inspections, problems flowing out, and frequent after-sales problems.

[0003] In addition, traditional testing methods often rely on a large number of dedicated hardware devices, resulting in high costs and large floor areas for the testing system. At the same time, the testing process is complex and cumbersome, requiring a large amount of manpower for equipment connection, parameter setting, and data recording and analysis. This not only has low efficiency but also easily introduces errors due to human operation mistakes. With the rapid development of automotive electronics technology, the functions of controllers are becoming increasingly complex. Traditional testing methods are difficult to achieve comprehensive coverage of various functional conditions within the limited production line time, and cannot fully detect potential software vulnerabilities and hardware compatibility problems. Moreover, for different models or batches of automotive controllers, the adaptability of traditional testing methods is poor, and frequent adjustments to the testing platform and testing programs are required, further increasing the testing cost and time cycle. Summary of the Invention

[0004] In view of the above technical problems, the present invention provides a method and system for simulating and testing automotive controllers at the production line end, aiming to achieve fast, efficient, comprehensive, and low-cost testing of automotive controllers at the production line end through an innovative simulation testing method, improve the product quality and production efficiency of automotive controllers, and ensure the safety and reliability of the entire vehicle.

[0005] The present invention is implemented by the following technical solutions: A method for simulating and testing automotive controllers at the production line end includes the following steps: S1: Collect test requirements and release relevant design materials and test samples; S2: Build a test bench, including a simulation test model, a simulation test interface, simulation closed-loop debugging, and bench integration debugging; S3: Develop simulation test cases and convert them into automated test scripts; S4: Conduct simulation tests and generate a test report.

[0006] Furthermore, the test requirements include the requirements for the detection of the vehicle's electrical functions and the requirements for the design changes of components.

[0007] Furthermore, the simulation test model specifically includes: according to the working principle and actual operation logic of the vehicle controller, simulating the internal signal processing flow of the vehicle controller, as well as the interaction mechanism between each controller and the response characteristics to peripheral devices, to ensure that the test model can truly reflect the controller performance.

[0008] Furthermore, the simulation test interface specifically includes: designing a simulation test interface to enable testers to set test parameters, start and stop the test, and view test data and result feedback. Among them, the changing trends of key data are displayed in a visual chart.

[0009] Furthermore, the simulation closed-loop debugging specifically includes: connecting the simulation test model to the actual controller hardware, enabling the controller to operate under the excitation of a virtual environment, and then feeding back the output of the controller to the model to form a closed loop to accurately verify the effectiveness of the control strategy.

[0010] Furthermore, the bench integration debugging specifically includes: comprehensively checking the compatibility and connection stability of each controller, and debugging and optimizing the model accuracy, interface response timeliness, and closed-loop communication reliability to ensure the efficient and stable operation of the entire simulation test bench.

[0011] Furthermore, step S3 is specifically as follows: relying on the function specifications of the test vehicle controller and various working condition requirements, designing test cases covering normal and abnormal scenarios, and clarifying each test step, expected input, and output; at the same time, converting the test cases into automated test scripts, and by optimizing the script logic and code structure, enabling the test cases to accurately drive the simulation test platform to automatically execute the test process.

[0012] Furthermore, step S4 is specifically as follows: assigning test tasks according to the skills and workload of testers, and testers carrying out specific tests according to the tasks, operating in the virtual environment according to the test process, recording various data in detail, and after the test is completed, sorting out the test report, including the test results and problem analysis content.

[0013] A production line-end vehicle controller simulation test system for implementing the above-mentioned production line-end vehicle controller simulation test method, including a data acquisition module, a simulation module, a test case development module, and a report generation module. Among them, the data acquisition module is used to collect test requirements and release relevant design materials and test samples; the simulation module is used to perform test model simulation, test interface simulation, closed-loop debugging simulation, and bench integration debugging; the test case development module is used to develop test cases and convert them into automated test scripts; the report generation module is used to form a test report after the test is implemented.

[0014] The beneficial effects of the present invention are as follows: The present invention specifically introduces virtual simulation testing technology, digitizes the part of the physical vehicle system ontology (digital twin), constructs a hardware-in-the-loop (HIL) simulation testing platform for the vehicle electrical system, realizes multi-level simulation testing of the electrical system in the production process, introduces the hardware-in-the-loop (HIL) simulation testing method in the process production link, establishes a virtual vehicle model, realizes the control of the physical vehicle electrical control system over the virtual vehicle, and constructs a hardware-in-the-loop simulation testing environment for the vehicle electrical control system.

[0015] The present invention realizes function testing, fault injection testing, and diagnostic function testing of electrical components in the early stage of trial vehicle assembly on the production line, supports the writing of automated test scripts, realizes efficient automated testing, discovers potential software problems in advance, rectifies them before mass vehicle assembly, and reduces the vehicle assembly risk. In terms of the design change testing of electrical components, for the software and hardware design changes of electrical components, the change status is detected to ensure the quality of mass vehicle assembly parts. In addition, for the reproduction, positioning, and analysis of after-sales feedback problems, through the method proposed by the present invention, the scope and depth of electrical detection in the vehicle production link are improved, and the risk after vehicle market launch is greatly reduced. Brief Description of the Drawings

[0016] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the following-described drawings are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on the structures shown in these drawings without creative efforts.

[0017] Figure 1 It is the system block diagram of the present invention. Detailed Embodiments

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the drawings in the embodiments of the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. Usually, the components of the embodiments of the present invention described and illustrated in the drawings here can be arranged and designed in various different configurations.

[0019] It should be noted that: similar reference numerals and letters denote similar items in the following drawings. Therefore, once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings.

[0020] The following will, with reference to the drawings, elaborate on some embodiments of the present invention. Without conflict, the following embodiments and the features in the embodiments can be combined with each other.

[0021] See Figure 1 , a simulation test method for automotive controllers at the production line end, including the following steps: S1: Collect test requirements and release relevant design materials and test samples; S2: Build a test bench, including a simulation test model, a simulation test interface, simulation closed-loop debugging, and bench integration debugging; S3: Develop simulation test cases and convert them into automated test scripts; S4: Conduct simulation tests and generate a test report.

[0022] In this embodiment, step S1 is specifically as follows: Import vehicle model test requirements, which include vehicle electrical function detection requirements and component design change requirements. In this stage, it is necessary to collect and organize test requirements and release relevant design materials and test samples.

[0023] In this embodiment, step S2 specifically includes: Build a test environment (simulation test bench). When building the simulation test bench, first construct a high-precision simulation test model. Based on the working principle and actual operation logic of the automotive controller, accurately simulate its internal signal processing flow, the interaction mechanism of each module, and the response characteristics to peripheral devices to ensure that the model can truly reflect the controller performance.

[0024] Then design an intuitive and fully functional simulation test interface to facilitate testers to conveniently set test parameters, start and stop tests, and clearly view test data and result feedback, such as displaying the change trend of key data in visual charts.

[0025] For simulation closed-loop development, connect the simulation test model to the actual controller hardware, make the controller run under the excitation of the virtual environment, and its output is then fed back to the model to form a closed loop to accurately verify the effectiveness of the control strategy.

[0026] Finally, conduct bench integration debugging, comprehensively check the compatibility and connection stability of each component, and strictly debug and optimize aspects such as model accuracy, interface response timeliness, and closed-loop communication reliability to ensure that the entire simulation test bench can operate efficiently and stably, providing a solid and reliable platform support for automotive controller testing.

[0027] In this embodiment, step S3 specifically includes: Simulation test development. Relying on the functional specifications of the test automotive controller and various working condition requirements, carefully design test cases covering normal and abnormal scenarios, and clarify each test step, expected input and output. At the same time, use professional tools to convert the test cases into automated test scripts, and optimize the script logic and code structure to enable it to accurately drive the simulation test platform to automatically execute the test process.

[0028] The test cases for normal scenarios include: Use Case 1 (High Voltage Power - on): Simulate that when the vehicle starts, after the VCU receives the key signal, it sequentially completes the low - voltage power - on self - check, closes the pre - charge circuit, and engages the main relay, and finally outputs a high - voltage ready status signal. The expected outputs include that the pre - charge voltage steadily rises to the target value (such as 400V) and the main relay closing success flag is triggered.

[0029] Use Case 2 (High Voltage Power - off): Test that when the vehicle shuts down, the VCU disconnects the main relay according to the key signal and releases the residual voltage to ensure the safe power - off of the high - voltage system. The expected output is that the voltage drops to the safe range (such as < 60V) after the relay disconnects and no fault code is triggered.

[0030] The test cases for abnormal scenarios include: Use Case 3 (Pre - charge Timeout): Simulate the failure of the pre - charge resistor, resulting in the pre - charge time exceeding the threshold (such as 5 seconds). The expected output is that the VCU triggers a fault code and performs a high - voltage power - off protection action.

[0031] Use Case 4 (Insulation Fault): Inject a simulated signal with an insulation resistance value lower than the safety threshold (such as < 500Ω / V) to verify whether the VCU can promptly cut off the high - voltage and report an insulation fault.

[0032] To convert the test cases into automated test scripts, the dSPACE SCALEXIO real - time system can be specifically used. Through the AutomationDesk automated test software, integrating Python scripts to achieve data parsing and processing, simulate input conditions such as key signals, battery voltages, and insulation detection signals, and automatically compare the actual outputs with the expected results. Additionally, script optimization: Split the test steps into independent modules (such as "signal injection → delay waiting → result capture"), improve reusability through function encapsulation; introduce an exception - handling mechanism to ensure that the script automatically retries and records error logs when the communication in the simulation platform is interrupted.

[0033] In this embodiment, step S4 specifically includes: Simulation test implementation. First, reasonably assign test tasks according to the skills and workload of the testers. The testers carry out specific tests according to the tasks, operate strictly in accordance with the test procedures in the virtual environment, and record various data in detail. After the test is completed, quickly organize the test report, clearly presenting the test results, problem analysis, etc. For the test cases that fail, the regression test process should be started, deeply investigate the root cause of the problem, adjust relevant parameters or fix defects and then test again.

[0034] Specifically, the simulation test implementation can be divided into task assignment and execution, problem closed-loop and regression testing. Among them, task assignment and execution: Hardware confirmation: Responsible for the wiring of the HIL bench and the debugging of the signal conditioning module to ensure the matching of the insulation detection analog circuit and the VCU interface. Test execution: Assign test tasks to on-site test engineers, select corresponding test cases according to the test work assigned by the task, execute the automation script, monitor the running status of the simulation test bench, and collect and store test data in real time (such as the status of the high-voltage relay, fault codes). Data recording: When testing the "pre-charge timeout" use case, record the pre-charge voltage curve, fault trigger timestamp, and associated CAN signals for subsequent analysis.

[0035] Problem closed-loop and regression testing: Defect analysis: If the "high-voltage power-on successful" use case fails, combined with the simulation log, it is found that the pre-charge voltage rise rate is abnormal, and it is located that the battery model parameters (such as the equivalent capacitance value) are set incorrectly. Regression testing: After adjusting the capacitance value in the battery model of the VCU software, trigger the regression test by issuing a software change, and verify the passing rate of all associated use cases (such as power-on, fault recovery) after correction.

[0036] The present invention also provides a production line-end vehicle controller simulation test system for implementing the above-mentioned production line-end vehicle controller simulation test method, including a data acquisition module, a simulation module, a use case development module, and a report generation module. Among them, the data acquisition module is used to collect test requirements and release relevant design materials and test samples; the simulation module is used to perform test model simulation, test interface simulation, closed-loop debugging simulation, and bench integration debugging; the use case development module is used to develop test cases and convert them into automation test scripts; the report generation module is used to generate a test report after the test implementation.

[0037] The application of the present invention can break the blank of scene application in this field of the industry, improve the full-life cycle quality assurance process from the R & D design of the vehicle electrical system to production inspection, and has great practical application value.

[0038] For the foregoing embodiments, for the sake of simple description, they are all expressed as a series of action combinations. However, those skilled in the art should know that this application is not limited by the described action sequence, because according to this application, some steps can be performed in other sequences or simultaneously. Secondly, those skilled in the art should also know that the embodiments described in the specification belong to preferred embodiments, and the actions involved are not necessarily essential to this application.

[0039] In the above embodiments, the basic principles, main features and advantages of the present invention are described. Those skilled in the art should understand that the present invention is not limited by the above embodiments. What is described in the above embodiments and the specification only illustrates the principles of the present invention. Without departing from the spirit and scope of the present invention, any modifications and changes made by those skilled in the art that do not depart from the spirit and scope of the present invention shall fall within the protection scope of the appended claims of the present invention.

Claims

1. A simulation test method for automotive controllers at the production line end, characterized in that, It includes the following steps: S1: Collect test requirements and release relevant design materials and test samples; S2: Build a test bench, including a simulation test model, a simulation test interface, simulation closed-loop debugging, and bench integration debugging; S3: Develop simulation test cases and convert them into automated test scripts; S4: Conduct simulation tests and generate test reports.

2. The simulation test method for an in-line automotive controller according to claim 1, wherein The test requirements include the detection requirements for the vehicle's electrical functions and the requirements for design changes of components.

3. The simulation test method for a production line-end vehicle controller according to claim 1, characterized in that, The simulation test model specifically includes: According to the working principle and actual operation logic of the vehicle controller, simulate the internal signal processing process of the vehicle controller, the interaction mechanism between controllers, and the response characteristics to peripheral devices, ensuring that the test model can truly reflect the controller performance.

4. The simulation test method for an in-line automotive controller according to claim 1, characterized in that The simulation test interface specifically includes: Design a simulation test interface to enable testers to set test parameters, start and stop tests, and view test data and result feedback. Among them, the changing trends of key data are displayed in visual charts.

5. The simulation test method for an in-line automotive controller according to claim 1, wherein The simulation closed-loop debugging specifically includes: Connect the simulation test model to the actual controller hardware, make the controller run under the excitation of the virtual environment, and feedback the output of the controller to the model to form a closed loop to accurately verify the effectiveness of the control strategy.

6. The simulation test method for the vehicle controller at the production line end according to claim 1, wherein, The bench integration debugging specifically includes: Comprehensively check the compatibility and connection stability of each controller, and debug and optimize the model accuracy, interface response timeliness, and closed-loop communication reliability to ensure the efficient and stable operation of the entire simulation test bench.

7. The simulation test method for an in-line automotive controller according to claim 1, characterized in that, Step S3 is specifically as follows: Relying on the function specifications of the test vehicle controller and various working condition requirements, design test cases covering normal and abnormal scenarios, and clarify each test step, expected input and output; at the same time, convert the test cases into automated test scripts, and by optimizing the script logic and code structure, enable the test cases to accurately drive the simulation test platform to automatically execute the test process.

8. A simulation test method for an in-line automotive controller according to claim 1, characterized in that Step S4 is specifically as follows: Assign test tasks according to the skills and workload of testers. Testers carry out specific tests according to the tasks, operate according to the test process in the virtual environment, record various data in detail, and after the test is completed, organize a test report, including test results and problem analysis content.

9. A production line-end automotive controller simulation test system for implementing the production line-end automotive controller simulation test method according to any one of claims 1 to 8, characterized in that, It includes a data acquisition module, a simulation module, a use case development module, and a report generation module. Among them, the data acquisition module is used to collect test requirements and release relevant design materials and test samples; the simulation module is used to conduct simulation of the test model, simulation of the test interface, closed-loop debugging simulation, and bench integration debugging; the use case development module is used to develop test cases and convert them into automated test scripts; the report generation module is used to generate a test report after the test is implemented.

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