PCBA test system for automobile power grid management module

Abstract

The invention discloses an automobile power grid management module PCBA test system, and the system comprises an integrated chemical station which integrates PCBA feeding, burning, testing and material combining functions, and achieves the automatic grabbing, burning, testing and material combining of PCBA through a mechanical arm. And the instrument test module is used for comprehensively detecting various functions and performance indexes of the module according to the product function characteristics of the automobile power grid management module, and the test platform is used for acquiring the acquired test data of the instrument test module so as to meet the test requirements of the power grid management module. The test of the instrument test module comprises a voltage acquisition circuit test, a current detection circuit test, a short circuit protection circuit test, an overvoltage wake-up circuit test, an overvoltage and undervoltage protection test, a CAN communication test, a hard wire wake-up circuit test, a dormant state test and a watchdog circuit function detection.

Description

Technical Field

[0001] This invention belongs to the field of automotive parts technology, and specifically relates to a PCBA testing system for automotive electrical grid management modules. Background Technology

[0002] The Power Net Guardian (PNG) module is an advanced automotive power management system designed to provide modern vehicles with a comprehensive, intelligent, and efficient power management solution. PNG's core function is to achieve comprehensive management of the vehicle's power system, ensuring efficient power path allocation and safe operation. It can monitor key parameters such as voltage and current in power circuits in real time and make rapid decisions based on the monitoring results, such as disconnecting faulty circuits or restoring power supply, thereby ensuring the stability and reliability of the vehicle's power system. Specifically, it includes:

[0003] PNG enables precise control of subsystem and load current, and real-time monitoring of parameters such as voltage and current in the DC-DC power supply circuit and battery power supply circuit. Upon detecting anomalies such as overvoltage, undervoltage, or overcurrent, PNG can quickly disconnect the corresponding output circuit to ensure normal power supply on the other side. PNG has rapid recovery capabilities; once the detected fault is cleared, it can quickly restore power supply, reducing vehicle function interruption time caused by power supply abnormalities.

[0004] Both outputs of the PNG have bidirectional current and voltage sampling capabilities, supporting bidirectional load driving. This means that in different power modes, the PNG can flexibly control the power output and distribution according to the vehicle's power status and configuration requirements. Even when the vehicle's power mode is off, the PNG still has load driving capacity, providing power support for necessary equipment or systems. In redundant power mode, the PNG has the function of disconnecting the output circuit to protect the entire power system.

[0005] The PNG (Power Controller Port) uploads its operating and fault status information via the CAN bus, enabling the vehicle's control system to monitor its operation in real time, facilitating centralized management and fault diagnosis. The PNG possesses both hardware and software fault monitoring capabilities; when a fault disappears, the MOS output can self-recover. Furthermore, the PNG supports MOS open-circuit, short-circuit, and loop fault monitoring, as well as current and temperature sampling functions, providing strong support for comprehensive monitoring and protection of the power system.

[0006] PNG integrates multiple safety protection functions, such as short-circuit protection, reverse connection protection, overvoltage protection, undervoltage protection, overtemperature protection, and overcurrent protection. These protection functions can take timely measures when corresponding faults are detected, cutting off the output circuit or implementing other protection strategies to effectively prevent equipment damage, fires, and other safety accidents caused by abnormal power supply. PNG also has fault diagnosis and handling functions, which can perform corresponding processing according to the detected fault type, and support forcibly opening or closing the output circuit through diagnostic commands, providing convenience for fault diagnosis and maintenance.

[0007] PNG intelligently controls all loads through software, achieving precise load power distribution control based on scenario and functional requirements. This intelligent control method can flexibly allocate power according to the actual operating status of the vehicle and user needs, improving power utilization efficiency and reducing energy consumption. PNG supports parameter configuration functions, meeting the differentiated power management needs of different vehicle models, and has good versatility and adaptability.

[0008] Therefore, the grid management module offers a highly attractive combination of features, driving its integration into mainstream electrical and electronic architectures. With the introduction of new centralized vehicle architectures, automakers are moving towards comprehensive electronic switching solutions. The grid management module has become commercially attractive due to the introduction of fewer, high-performance onboard computers and regional intermediate layers for sub-function allocation. To reduce overall system costs, some automakers have not yet fully transitioned to electronic fuses, instead using traditional fuses to protect some loads with lower functional requirements. This trend towards primarily using electronic fuses will continue as the overall electrical and electronic architecture becomes more integrated. Besides better controllability, this also provides the option to move grid components to inaccessible installation spaces or replace centralized channels with separately monitored load paths. However, when testing the PCBA of an automotive grid management module, traditional testing methods may suffer from low testing efficiency, low testing accuracy, and an inability to fully simulate vehicle operating conditions, making it difficult to meet stringent requirements for product quality and performance. Summary of the Invention

[0009] One embodiment of the present invention is a PCBA testing system for automotive electrical grid management modules, comprising: an integrated chemical station, which integrates PCBA feeding, programming, testing, and assembly functions, and realizes automatic PCBA grabbing, programming, testing, and assembly through a robotic arm;

[0010] The instrument testing module is used to comprehensively test the various functions and performance indicators of the automotive electrical network management module based on its product functional characteristics.

[0011] The testing platform acquires the test data collected by the instrument testing module to meet the testing requirements of the power grid management module.

[0012] The instrument testing module includes voltage acquisition circuit testing, current detection circuit testing, short circuit protection circuit testing, overvoltage wake-up circuit testing, overvoltage and undervoltage protection testing, CAN communication testing, hard-wired wake-up circuit testing, sleep state testing, and watchdog circuit function testing.

[0013] The circuitry of the test platform includes a programmable gain high-performance bipolar instrumentation amplifier, a bidirectional suppression circuit, and a linear optocoupler circuit.

[0014] The test platform performs filtering processing on the obtained signal data, including median filtering, Butterworth low-pass filtering, and weighted recursive average filtering algorithms. Attached Figure Description

[0015] The above and other objects, features, and advantages of exemplary embodiments of the present invention will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings. Several embodiments of the invention are illustrated in the drawings by way of example and not limitation, wherein:

[0016] Figure 1 A schematic diagram of PNG system interaction according to one embodiment of the present invention. Detailed Implementation

[0017] like Figure 1 The PNG system diagram and interaction block diagram shown depict the intelligent grid management module (PNG) monitoring the voltage, current, and other parameters of both circuits (DC-DC power supply circuit and battery power supply circuit) in real time. If voltage or current is abnormal, it quickly disconnects the output circuit on that side to ensure normal power supply to the other side. The module has rapid recovery capability; if the detected fault is cleared, it can quickly recover. The intelligent grid management module has bidirectional load capacity; both outputs have bidirectional current and voltage sampling, and support undervoltage, overvoltage, overcurrent, and overtemperature protection. It has load capacity even when the vehicle power supply is off; it supports writing vehicle configuration words and has the function of disconnecting the output circuit in redundant power supply mode. This module needs to upload its operating status and fault status via the CAN bus. It has hardware and software fault monitoring; if the fault disappears, the MOS output can self-recover; it supports MOS open circuit, short circuit, and circuit fault monitoring; and it supports current and temperature sampling.

[0018] The table below is a functional test list for PNG.

[0019]

[0020]

[0021]

[0022] According to one or more embodiments, a PCBA testing system for an automotive electrical grid management module is disclosed. Based on an integrated workstation design, it adopts an automated production line process, integrating PCBA loading, programming, testing, and assembly into a single workstation. This integrated design reduces the transmission time and labor costs of PCBAs between different workstations, improving production efficiency. By rationally utilizing the scheduling of robotic arms, the automatic grasping, programming, testing, and assembly of PCBAs are achieved, making the entire process more automated and intelligent, reducing the impact of human factors on the production process, and improving product quality and consistency.

[0023] The entire process includes multiple steps such as heat sink loading, housing photolithography, venting flow testing, PCBA loading, programming, testing, assembly, PCBA B-cover attachment, connector soldering, adhesive sealing, heat sink attachment, high-temperature curing of sealant, airtightness testing, high-temperature aging, and EOL testing. By optimizing the flow and layout of these steps, efficient and orderly production is achieved, ensuring product quality and performance.

[0024] Based on the functional characteristics of PNG products, the testing system has developed a series of targeted instrument testing methods to comprehensively test various functions and performance indicators of PNG. These testing methods cover multiple aspects, including voltage acquisition circuit testing, current detection circuit testing, short-circuit protection circuit testing, overvoltage wake-up circuit testing, overvoltage and undervoltage protection testing, CAN communication testing, hard-wired wake-up circuit testing, sleep state testing, and watchdog circuit function testing, ensuring that PNG can operate normally under different working conditions and meet design requirements.

[0025] Voltage acquisition circuit test: With the MOSFET normally turned on, the accuracy of the voltage acquisition circuit is verified by detecting the voltage value at a specific test point. This ensures that PNG can acquire the voltage information of the DC-DC power supply circuit and the battery power supply circuit in real time and accurately, providing reliable data support for power management.

[0026] Current detection circuit test: By passing a certain amount of current between the DCDC terminal and the BATT terminal and detecting the voltage value at the corresponding test point, the accuracy of the current detection circuit is verified, enabling PNG to accurately monitor the current in the power supply circuit and providing a basis for overcurrent protection and other functions.

[0027] Short-circuit protection circuit test: With the MOSFET in the on state, apply voltage to a specific test point to verify the effectiveness of the short-circuit protection circuit, ensuring that PNG can cut off the output in time when a short circuit occurs in the output circuit, thus protecting the power supply system and related equipment.

[0028] Overvoltage wake-up circuit test: By changing the power supply voltage, the voltage change at a specific test point is detected to verify the function of the overvoltage wake-up circuit and ensure that PNG can take timely measures to wake up the system or execute the corresponding protection strategy when the power supply voltage rises abnormally.

[0029] Overvoltage and undervoltage protection test: Verify the protection function of PNG when the power supply voltage exceeds or falls below the specified range, and ensure that it can cut off the power circuit in time under abnormal voltage conditions to protect the power system and related equipment from damage.

[0030] CAN communication test: This test checks whether the CAN communication between the PNG and the vehicle control system is normal, ensuring that the PNG can upload information such as working status and fault status in real time and accurately, so as to achieve effective interaction with the whole vehicle system.

[0031] Hard-wire wake-up circuit test: By detecting the voltage value at specific test points, the function of the hard-wire wake-up circuit is verified to ensure that PNG can wake up in time when it receives the hard-wire wake-up signal, thus providing support for the start-up and operation of the vehicle.

[0032] Sleep state test: Detect the voltage status of PNG in sleep state to verify the normality of its sleep function and ensure that PNG can enter a low-power sleep state after the vehicle power is turned off, thereby reducing energy consumption.

[0033] Watchdog circuit function test: By applying voltage to a specific test point and detecting voltage changes at other relevant test points, the function of the watchdog circuit is verified, ensuring that PNG can be reset in time and resume normal operation when a software or hardware fault occurs.

[0034] Simulated vehicle operating condition testing: This test covers frequent forward and reverse switching scenarios simulating full vehicle operating conditions. It utilizes a self-developed simulated detection circuit module, employing high-performance components such as the AD620 programmable gain high-performance bipolar instrumentation amplifier, and a P6KETVS bidirectional suppression circuit. This effectively eliminates high-voltage pulse interference caused by forward and reverse switching between DC-DC and BAT-DCDC circuits during simulated full vehicle operating conditions, improving the accuracy and reliability of the test. Simultaneously, a linear optocoupler HCNR201 circuit is added for isolation before the sampling signal enters the board for reading, further improving the stability and accuracy of the test signal and ensuring the authenticity and reliability of the test results.

[0035] The entire sampling and testing platform is self-built based on a platform-based sampling module. This testing platform can be customized and optimized according to the specific testing needs of PNG, and has greater flexibility and adaptability, thus better meeting the testing requirements of PNG.

[0036] Furthermore, a combined filtering method was incorporated into the testing software. Median filtering was used to remove impulse noise, followed by Butterworth low-pass filtering to handle Gaussian noise, primarily addressing vibration interference from the high-speed chain. After the signal enters the board's DAQ sampling, a weighted recursive average filtering algorithm is applied. After a period of debugging and verification, considering the hysteresis of the product signal output, a first-order hysteresis parameter was added for adjustment. The application of these filtering algorithms effectively improved the quality of the test signal, reduced the impact of external interference on the test results, and ensured the stability and accuracy of the test results.

[0037] Through the optimization of the aforementioned testing platform and algorithms, the entire testing station can achieve a highly efficient testing process, with a test cycle time controlled within 50 seconds, completing the entire process of PCBA loading, programming, testing, and assembly. This not only improves production efficiency but also ensures product quality consistency, providing strong technical support for the large-scale production and application of automotive electrical system management modules.

[0038] In summary, the PNG PCBA testing system of this disclosure adopts an automated production line process, integrating PCBA loading, programming, testing, and assembly into a single workstation. Through the scheduling of robotic arms, it achieves automatic PCBA gripping, programming, testing, and assembly, improving production efficiency and product quality. Based on the functional characteristics of PNG products, a series of targeted instrument testing methods are developed, such as testing the product's power-on status under different operating conditions, voltage acquisition circuit testing, current detection circuit testing, short-circuit protection circuit testing, overvoltage wake-up circuit testing, overvoltage and undervoltage protection testing, CAN communication testing, hard-wired wake-up circuit testing, sleep state testing, and watchdog circuit function testing, comprehensively testing various functions and performance indicators of the PNG. We independently built a sampling and testing platform based on our self-developed platform-based sampling module. It uses high-performance components such as the AD620 programmable gain high-performance bipolar instrumentation amplifier, as well as P6KETVS bidirectional suppression circuits and HCNR201 linear optocoupler circuits to improve sampling accuracy and anti-interference capabilities. We also incorporated combined filtering methods into the testing software, using median filtering, Butterworth low-pass filtering, and weighted recursive average filtering algorithms to address vibration interference generated by the double-speed chain and ensure the stability of the test results.

[0039] Therefore, the technical effects achieved by this invention include:

[0040] (1) Improve the level of intelligence in automotive power management.

[0041] PNG's precise control and integration of multiple intelligent functions enable comprehensive, real-time, and accurate management of automotive power systems. This allows it to better adapt to the development needs of modern automotive electronic and electrical architectures, improve the reliability and safety of power systems, and provide strong support for the intelligent and electronic development of automobiles.

[0042] (2) Enhance the safety and reliability of the power supply system.

[0043] By integrating multiple safety protection functions, PNG can react quickly in various abnormal situations, effectively protecting the power system and related equipment from damage, reducing the risk of failure, and improving the overall safety and reliability of the automotive power system.

[0044] (3) Improve production efficiency and product quality.

[0045] The application of automated production line processes and targeted PCBA testing methods has enabled automated production and efficient testing of PCBAs, improving production efficiency while ensuring product quality consistency and better meeting market demands.

[0046] (4) To meet the differentiated needs of different vehicle models.

[0047] PNG supports parameter configuration, which can meet the different power management needs of different vehicle models. It has good versatility and adaptability, reducing development costs and development cycle.

[0048] (5) Optimize test accuracy and stability.

[0049] The self-built testing platform and optimized testing algorithms have effectively improved testing accuracy and stability, enabling more accurate detection of various performance indicators of PNG, and providing strong support for product quality control.

[0050] It is worth noting that although the foregoing has described the spirit and principles of the present invention with reference to several specific embodiments, it should be understood that the present invention is not limited to the disclosed specific embodiments, and the division of aspects does not imply that the features in these aspects cannot be combined; such division is merely for the convenience of description. The present invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. An automotive electrical network management module (PCBA) test system, characterized in that, The utility model relates to an integrated test platform for automobile power grid management module, which comprises an integrated work station, an instrument test module and a test platform. The integrated work station integrates PCBA loading, burning, testing and material mixing functions, and realizes automatic grabbing, burning, testing and material mixing of PCBA through a mechanical arm. The instrument test module is used for comprehensively detecting various functions and performance indexes of the automobile power grid management module according to product function characteristics of the automobile power grid management module. The test platform acquires collected test data of the instrument test module and realizes test requirements of the power grid management module.

2. The system of claim 1, wherein, The test of the instrument test module includes voltage acquisition circuit test, current detection circuit test, short-circuit protection circuit test, overvoltage wake-up circuit test, overvoltage and undervoltage protection test, CAN communication test, hard-wire wake-up circuit test, sleep state test and watchdog circuit function detection.

3. The system of claim 1, wherein, The circuit of the test platform comprises a programmable gain high-performance bipolar instrument amplifier, a bidirectional suppression circuit and a linear optocoupler circuit.

4. The system of claim 3, wherein, The test platform performs filtering processing on obtained signal data, including median filtering, Butterworth low-pass filtering and weighted recursive average filtering algorithm.

5. The system of claim 1, wherein, The integrated work station further comprises a housing radiator loading device for loading a housing radiator, a housing photoetching device for photoetching processing of the housing, a gas permeable sheet flow test device for testing the flow of the gas permeable sheet, a connector welding device for welding a connector, a dispensing sealing device for dispensing and sealing PCBA, a radiator locking device for locking the radiator, a sealant high-temperature curing device for high-temperature curing of the sealant, an air tightness detection device for detecting the air tightness of PCBA, a high-temperature aging device for high-temperature aging test of PCBA and an EOL test device for final product test. The voltage acquisition circuit test comprises detecting the voltage value of a specific test point in the normal on state of a MOS tube to verify the accuracy of the voltage acquisition circuit and ensure that the voltage information of a DCDC power supply loop and a storage battery power supply loop can be collected in real time and accurately. The current detection circuit test comprises passing a certain size of current between a DCDC end and a BATT end and detecting the voltage value of a corresponding test point to verify the accuracy of the current detection circuit. The short-circuit protection circuit test comprises applying voltage to a test point in the on state of a MOS tube to verify the effectiveness of the short-circuit protection circuit and ensure that the output loop is timely cut off when a short circuit occurs in the output loop. The overvoltage wake-up circuit test comprises changing the power supply voltage and detecting the voltage change of a test point to verify the function of the overvoltage wake-up circuit and ensure that the system is woken up or a protection strategy is executed when the power supply voltage abnormally rises. The overvoltage and undervoltage protection test comprises verifying the protection function of the automobile power grid management module when the power supply voltage exceeds or is lower than the specified range to ensure that the power supply loop is timely cut off in the voltage abnormal condition. The CAN communication test comprises detecting whether the CAN communication between the automobile power grid management module and a vehicle control system is normal to ensure that the working state and fault state information are timely and accurately uploaded. The hard-wire wake-up circuit test comprises ​ ​ ​ 6. The system of claim 2, wherein, ​ ​ 7. The system of claim 2, wherein, ​ ​ 8. The system of claim 2, wherein, ​ ​ 9. The system of claim 1, wherein, ​ ​ 10. The system of claim 1, wherein, ​ ​ 11. The system of claim 1, wherein, ​ ​ 12. The system of claim 1, wherein, ​ Detect the voltage value of the specific test point to verify the function of the hard-wire wake-up circuit and ensure that the automotive power grid management module wakes up in time when receiving the hard-wire wake-up signal.

13. The system of claim 1, wherein, The sleep state test comprises: Detect the voltage state of the automotive power grid management module in the sleep state to verify the normality of its sleep function and ensure that it enters the low-power sleep state after the vehicle is powered off.

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