Simulation system for vehicle safety airbag development

Abstract

The invention relates to a simulation system for vehicle safety air bag development, and the system comprises a multi-type sensor simulation module which comprises a satellite sensor simulation signal array unit, a central sensor simulation subunit, and an inertia measurement sensor simulation subunit; the air bag control module is connected with the multi-type sensor simulation module and the micro-control module, and is used for receiving the sensor signals output by the multi-type sensor simulation module, performing an air bag safety test according to the sensor signals, and transmitting a test result to the script control module through the micro-control module or a self communication interface; the micro-control module is connected with the multi-type sensor simulation module and the script control module, and is used for receiving a test configuration instruction of the script control module, controlling signal generation and fault injection of the multi-type sensor simulation module based on the test configuration instruction, and collecting a system operation state and response data of the airbag control module in real time; and a script control module.

Description

Technical Field

[0001] This application relates to the field of electronic control and sensor technology, and in particular to a simulation system for the development of vehicle airbags. Background Technology

[0002] In a vehicle's passive safety system, the airbag control unit (ACU) is the core decision-making component that ensures the safety of occupants in a collision. It uses dynamic vehicle signals collected by various types of inertial sensors to make accurate decisions on collision recognition and airbag triggering. Each type of sensor plays a different and irreplaceable role in the system.

[0003] Currently, development teams not only need to evaluate sensor behavior under real-vehicle operating conditions, but also need to conduct extensive repeatable, controllable, and injectable fault tests in laboratory environments. For cost, safety, and efficiency reasons, an increasing number of projects are introducing analog sensors early on to replace real sensors or to compare them with real sensors. However, existing sensor simulation systems typically only output a single interface signal, limiting their functionality. Summary of the Invention

[0004] Therefore, it is necessary to provide a simulation system for the development of vehicle airbags to address the aforementioned technical problems.

[0005] In a first aspect, this application provides a simulation system for developing vehicle airbags. The system includes:

[0006] The multi-type sensor simulation module includes a satellite sensor simulation signal array unit, a central sensor simulation subunit, and an inertial measurement sensor simulation subunit. The multi-type sensor simulation module is used to simulate different types of sensor signals and transmit them to the airbag control module.

[0007] The airbag control module is connected to the multi-type sensor simulation module and the microcontroller module. It is used to receive sensor signals output by the multi-type sensor simulation module, perform airbag safety tests based on the sensor signals, and transmit the test results to the script control module through the microcontroller module or its own communication interface.

[0008] The microcontroller module is connected to the multi-type sensor simulation module and the script control module. It is used to receive test configuration instructions from the script control module, control the signal generation and fault injection of the multi-type sensor simulation module based on the test configuration instructions, collect the system operating status and airbag control module response data in real time, and transmit the operating status and response data to the script control module.

[0009] The script control module is used to send test configuration commands to the microcontroller module and generate test reports based on the running status and response data transmitted by the microcontroller module.

[0010] In one embodiment, the satellite sensor analog signal array unit includes at least two independent analog circuit units, each corresponding to one signal channel, and is connected to the airbag control module through an independent signal channel.

[0011] In one embodiment, the satellite sensor analog signal array unit includes an input interface channel, a signal voltage divider and current limiting network, a comparison amplifier circuit, a synchronization pulse output module, and a programmable load control circuit.

[0012] In one embodiment, the central sensor analog subunit includes a serial peripheral communication interface, which includes a chip select pin, a serial clock pin, a master output slave input pin, and a slave output master input pin.

[0013] The serial clock pin, the master output slave input pin, and the slave output master input pin are respectively connected to the serial peripheral communication master interface pins of the airbag control module. The chip select pin of the central sensor analog subunit is electrically connected to the first input / output control pin of the microcontroller module, which is used to form a control link between the central sensor analog subunit and the airbag control module by controlling the level of the chip select pin.

[0014] In one embodiment, the inertial measurement sensor simulation subunit includes a serial peripheral communication interface. The inertial measurement sensor simulation subunit shares the serial clock pin, master output slave input pin, and slave output master input pin of the airbag control module with the central sensor simulation subunit. The chip select pin of the inertial measurement sensor simulation subunit is electrically connected to the second input / output control pin of the microcontroller module.

[0015] In one embodiment, the system further includes:

[0016] The safety verification unit is connected to the ignition control unit of the microcontroller module and the airbag control module. It is used to receive multi-type sensor simulation data transmitted by the microcontroller module and to feed back the verification result identifier of the multi-type sensor simulation data to the microcontroller module. If the verification result is successful, the ignition command is sent to the ignition control unit of the airbag control module.

[0017] In one embodiment, the signal voltage divider and current limiting network includes a first voltage divider and current limiting branch and a reference level branch. The input terminal of the first voltage divider and current limiting branch is connected to the signal output terminal of the input interface channel, and is used to divide and current limit the input sensor signal before outputting it to the positive input terminal of the comparator amplifier circuit. The reference level branch is connected to the signal output terminal of the input interface channel, and is used to provide a reference level after dividing the input sensor signal to achieve dynamic matching and filtering of signal amplitude.

[0018] In one embodiment, the comparison amplifier circuit includes an operational amplifier, a first resistor, a second resistor, and a feedback resistor. The positive input terminal of the operational amplifier is connected to the output terminal of the first voltage divider and current limiting branch. The negative input terminal is connected to a reference voltage through the first resistor and grounded through the second resistor. The output terminal is connected to the positive input terminal through the feedback resistor to form a hysteresis characteristic. The operational amplifier is used to compare the voltage-divided and current-limited sensor signal input at the positive input terminal with the reference voltage at the negative input terminal. When the voltage amplitude of the sensor signal exceeds the comparison threshold, the output terminal outputs a flip signal.

[0019] In one embodiment, the synchronization pulse output module includes a third resistor, one end of which is connected to the output of the operational amplifier, and the other end is used to connect to the input pin of an external controller. The synchronization pulse output module is used to convert the flip signal output by the operational amplifier into a synchronization pulse signal and transmit it to the external controller so that the external controller can capture the communication beat of the sensor signal or realize data synchronization.

[0020] In one embodiment, the script control module includes a collision curve editing submodule, which supports importing acceleration time-domain curve data from real vehicle collision tests.

[0021] The aforementioned simulation system for vehicle airbag development includes at least the following beneficial effects:

[0022] The embodiments provided in this disclosure integrate the acceleration sensor, pressure sensor, central sensor, and inertial sensor used in the application of the airbag control module into a single platform, covering multi-scenario testing. This allows for the simulation of various collision scenarios before the airbag control module undergoes bench testing, thus fully validating the product. Furthermore, it supports automated test scripts for control and is compatible with multi-cascaded ignition chip solutions.

[0023] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this disclosure. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments or conventional technologies of this disclosure, the accompanying drawings used in the description of the embodiments or conventional technologies will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this disclosure. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 A schematic diagram of a simulation system for developing a vehicle airbag in one embodiment;

[0026] Figure 2 This is a schematic diagram of a satellite sensor analog signal array unit in one embodiment;

[0027] Figure 3 This is a schematic diagram of sensors from different manufacturers in one embodiment. Detailed Implementation

[0028] To enable those skilled in the art to better understand the technical solutions of this disclosure, the technical solutions in the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings.

[0029] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this disclosure are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this disclosure described herein can be implemented in orders other than those illustrated or described herein. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this disclosure. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this disclosure as detailed in the appended claims. The terms "comprising," "including," or any other variations thereof are intended to cover a non-exclusive inclusion, such that a process, method, product, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, product, or apparatus. Without further limitation, the presence of other identical or equivalent elements in a process, method, product, or apparatus that includes said elements is not excluded. For example, the use of terms such as "first," "second," etc., is to denote names and does not indicate any specific order.

[0030] Figure 1 This is a schematic diagram of a simulation system for developing vehicle airbags in one embodiment.

[0031] The satellite sensor analog signal array unit can be used to simulate PSI5 (Automotive Sensor Communication Protocol) bus satellite sensors, such as acceleration sensors and pressure sensors, in locations such as the front compartment, B-pillar, and sill of a vehicle.

[0032] In one embodiment of this disclosure, Figure 2 This is a schematic diagram of a satellite sensor analog signal array unit in one embodiment. The satellite sensor analog signal array unit includes at least two independent analog circuit units. Each independent analog circuit unit includes an input interface channel, a signal voltage divider and current limiting network, a comparator amplifier circuit, and a programmable load control circuit. The input interface module (J111) is used to receive multiple PSI5 signal inputs from the airbag control unit or the sensor side, for example... Figure 1 The input signal is connected to channels PSI5_A through PSI5_F. After current limiting by the resistor divider network R3 and R7, one signal is input to the positive input (IN+) of the comparator amplifier module, while the other part is provided with a reference level by the voltage divider R13 and R14 for dynamic matching and filtering of the signal amplitude. The comparator amplifier module consists of operational amplifier U2 (model TLV3201AIDBVR), whose negative input (IN−) is connected to the reference voltage VCC_COMP_REF, and the comparison threshold is set by resistors R10 and R16. The comparator output is hysteresis-promoted by feedback resistor R17 to improve signal stability and anti-jitter capability. When the voltage amplitude of the input PSI5 signal exceeds the threshold, the comparator output flips, forming a synchronization pulse signal SYNC_PULSE. This pulse signal is output to the controller's input pin (4201 INPUT IO) through the current limiting resistor R8, and is used by the subsequent inertial measurement unit (IMU) to capture the communication beat or data synchronization of the PSI5 signal.

[0033] The system also includes a programmable load control circuit for dynamically adjusting the termination impedance and operating state of each PSI5 channel. This part consists of multiple NMOS transistors Q1 to Q4 (model 2N7002), whose gates are driven by control signals RLoad_Control_1 to RLoad_Control_4, respectively. The MCU controls the logic levels of these control signals, and periodically outputs a set of level sequences to RLoad_Control_1 via the GPIO (General Purpose Input / Output) interface of the microcontroller unit (MCU) to realize PSI5 communication bits. This enables simulated load switching, open-circuit state simulation, and fault injection testing for each PSI5 channel. The power supply section provides a stable 3.3V voltage (from LDO 3.3V) to power the comparator and load control circuit. The power supply port is decoupled using capacitor C1 (0.1μF) to ensure the stability of the comparison output. This circuit system realizes PSI5 signal detection, threshold comparison, and synchronization pulse capture, and, combined with the controllable load module, realizes multi-state simulation of sensor signals. This structure is suitable for scenarios such as airbag control unit (ACU) input port testing, PSI5 communication link verification, and sensor signal debugging. It has the advantages of high integration, strong scalability, and good compatibility with automated testing.

[0034] In one embodiment of this disclosure, the central sensor simulation subunit is used to simulate the high-bandwidth impact acceleration sensor built into the airbag control module. It includes an SPI (Serial Peripheral Interface) slave adapter circuit and an acceleration data generation module. The SPI slave adapter circuit includes a chip select pin (CS1), a serial clock pin (SCLK), a master output slave input pin (MOSI), and a slave output master input pin (multiple-input single-output, MISO). SCLK, MOSI, and MISO are directly connected to the ACU's SPI master interface, and CS1 is electrically connected to the MCU's first GPIO pin (e.g., PA0), with communication enabled controlled by the MCU. The acceleration data generation module incorporates a DAC (Digital to Analog Converter) and a data buffer unit, supporting the generation of high-bandwidth impact acceleration data. Figure 3This is a schematic diagram of sensors from different manufacturers in one embodiment. This system can simulate central sensors and IMU sensors from multiple manufacturers to ensure compatibility with different ACU modules. All three types of sensors use a 32-bit frame structure, but differ in their instruction domain, state, and cyclic redundancy check (CRC) mechanisms. Through dynamic collision curve input via a host computer or test script, the ACU module can acquire acceleration and vehicle attitude sensor data during actual collisions, meeting the unified verification requirements for multi-protocol sensor inputs during the development and testing phase. It can cover multi-sensor data from multiple collision scenarios. The edited collision curve template is bound to the test process. During testing, the script control module associates and stores the raw collision curve data with the actual output signals of the multi-type sensor simulation modules and the response data of the airbag control module. This facilitates subsequent analysis of the ACU's decision-making accuracy under real collision curve inputs, such as whether ignition is correctly triggered at the peak of the collision. These simulated sensors can be synchronously monitored by the ACU's ASIC (Application-Specific Integrated Circuit) ignition chip CCL1600B SAM module to unlock the ignition safety module for subsequent ignition decisions. Furthermore, the 32-bit data sensor simulation module fully verifies the CCL1600B's data monitoring and analysis capabilities, facilitating the construction of various fault and abnormal states under controlled conditions, thus improving the system's ability to detect and tolerate erroneous data.

[0035] In one embodiment of this disclosure, the inertial measurement unit (IMU) simulation subunit consists of an SPI time-division multiplexing circuit, a multi-dimensional data generation module, and a Kalman filter subunit. The SPI time-division multiplexing circuit shares the SCLK, MOSI, and MISO pins of the central sensor simulation subunit. The independent chip select pin (CS2) is electrically connected to the second GPIO pin (such as PA1) of the MCU. It is controlled by the MCU to access the SPI bus in a time-division manner. The multi-dimensional data generation module can generate three-axis acceleration and three-axis gyroscope data. The Kalman filter subunit performs real-time fusion of the raw data and outputs the vehicle roll angle and pitch angle, replicating the data processing logic of the vehicle IMU and supporting the roll collision recognition of the ACU.

[0036] The multi-type sensor simulation module simulates the signal parameters of all sub-units, such as the PSI5 current amplitude, the central sensor acceleration peak value, the IMU attitude angle range, and fault injection commands, such as open / short circuit trigger timing. All of these are driven by control signals issued by the MCU. The satellite sensor simulation signal array unit controls the gate level of the NMOS transistor through the MCU's GPIO interface to realize load switching and fault injection. The central sensor and IMU simulation sub-units receive data to generate parameters through the MCU's SPI interface and control communication enable through the CS pin.

[0037] The multi-type sensor simulation module transmits analog signals to the ACU through a dedicated interface. Satellite sensor signals are transmitted through the PSI5 bus, with each channel outputting independently. It supports parallel simulation of multi-location distributed sensors. The central sensor and IMU signals are transmitted in a time-division manner through the SPI bus, with no signal distortion.

[0038] In one embodiment of this disclosure, the airbag control unit (ACU) reproduces the real working scenario by receiving analog sensor signals to verify its collision decision and safety control logic. It receives analog signals from satellite sensors through the PSI5 bus interface and analog signals from the central sensor / IMU through the SPI master interface in a time-division manner. Based on the analog signals, it performs signal filtering, protocol parsing, collision identification, and ignition decision-making processes. It outputs an ignition command only when the collision threshold is met and the safety verification unit is enabled. It transmits the test status code, fault code, and key parameters to the microcontroller module or directly uploads them to the script control module through the SPI slave interface or CAN / Ethernet interface.

[0039] In one embodiment of this disclosure, the microcontroller module receives test configuration instructions from the script control module, converts them into hardware-executable control signals, such as GPIO levels and SPI timing, and controls the multi-type sensor simulation modules to generate specified signals. The system's operating status is collected in real time, such as whether the simulation module channels are normal, whether faults have been successfully executed, and airbag control module response data, such as ignition commands, fault codes, and data parsing results. The acquisition frequency matches the test scenario. The collected status and response data are encapsulated according to the script control module's protocol format and uploaded via a UART / CAN Ethernet interface to ensure data timing synchronization.

[0040] In one embodiment of this disclosure, the script control module provides a visual interface or script editing function, supporting user configuration of test parameters and generating test configuration commands to be sent to the microcontroller module. It receives running status and response data uploaded by the microcontroller module, analyzes test compliance in real time (e.g., whether analog signals conform to the protocol, whether ACU decisions are correct), and calculates test pass rate and fault diagnosis coverage. It automatically generates standardized reports containing test parameters, key curves, result statistics, and anomaly data lists, enabling traceability of test results.

[0041] The aforementioned simulation system for vehicle airbag development integrates acceleration sensors, pressure sensors, central sensors, and inertial sensors used in the airbag control module application onto a single platform. It covers multiple testing scenarios and can perform combined simulations of various collision conditions before the airbag control module undergoes bench testing, thus fully validating the product. Furthermore, it supports automated test scripts for control and is compatible with multi-cascaded ignition chip solutions.

[0042] It should be understood that although the steps in the flowcharts of the embodiments described above are shown sequentially according to the arrows, these steps are not necessarily executed in the order indicated by the arrows. Unless explicitly stated herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, at least some steps in the flowcharts of the embodiments described above may include multiple steps or multiple stages. These steps or stages are not necessarily completed at the same time, but can be executed at different times. The execution order of these steps or stages is not necessarily sequential, but can be performed alternately or in turn with other steps or at least some of the steps or stages of other steps.

[0043] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0044] The embodiments described above are merely illustrative of several implementations of this disclosure, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this patent disclosure. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this disclosure, and these all fall within the protection scope of this disclosure. Therefore, the protection scope of this disclosure should be determined by the appended claims.

Claims

1. A simulation system for vehicle airbag development, characterized in that, The system includes: The multi-type sensor simulation module includes a satellite sensor simulation signal array unit, a central sensor simulation subunit, and an inertial measurement sensor simulation subunit. The multi-type sensor simulation module is used to simulate different types of sensor signals and transmit them to the airbag control module. The airbag control module is connected to the multi-type sensor simulation module and the microcontroller module. It is used to receive sensor signals output by the multi-type sensor simulation module, perform airbag safety tests based on the sensor signals, and transmit the test results to the script control module through the microcontroller module or its own communication interface. The microcontroller module is connected to the multi-type sensor simulation module and the script control module. It is used to receive test configuration instructions from the script control module, control the signal generation and fault injection of the multi-type sensor simulation module based on the test configuration instructions, collect the system operating status and airbag control module response data in real time, and transmit the operating status and response data to the script control module. The script control module is used to send test configuration commands to the microcontroller module and generate test reports based on the running status and response data transmitted by the microcontroller module.

2. The system according to claim 1, characterized in that, The satellite sensor analog signal array unit includes at least two independent analog circuit units, each corresponding to one signal channel, and is connected to the airbag control module through an independent signal channel.

3. The system according to claim 2, characterized in that, The satellite sensor analog signal array unit includes an input interface channel, a signal voltage divider and current limiting network, a comparison amplifier circuit, a synchronization pulse output module, and a programmable load control circuit.

4. The system according to claim 1, characterized in that, The central sensor analog subunit It includes a serial peripheral communication interface, which includes a chip select pin, a serial clock pin, a master output / slave input pin, and a slave output / master input pin. The serial clock pin, the master output slave input pin, and the slave output master input pin are respectively connected to the serial peripheral communication master interface pins of the airbag control module. The chip select pin of the central sensor analog subunit is electrically connected to the first input / output control pin of the microcontroller module, which is used to form a control link between the central sensor analog subunit and the airbag control module by controlling the level of the chip select pin.

5. The system according to claim 4, characterized in that, The inertial measurement sensor simulation subunit includes a serial peripheral communication interface. The inertial measurement sensor simulation subunit shares the serial clock pin, master output slave input pin, and slave output master input pin of the airbag control module with the central sensor simulation subunit. The chip select pin of the inertial measurement sensor simulation subunit is electrically connected to the second input / output control pin of the microcontroller module.

6. The system according to claim 1, characterized in that, The system also includes: The safety verification unit is connected to the ignition control unit of the microcontroller module and the airbag control module. It is used to receive multi-type sensor simulation data transmitted by the microcontroller module and to feed back the verification result identifier of the multi-type sensor simulation data to the microcontroller module. If the verification result is successful, the ignition command is sent to the ignition control unit of the airbag control module.

7. The system according to claim 3, characterized in that, The signal voltage divider and current limiting network includes a first voltage divider and current limiting branch and a reference level branch. The input terminal of the first voltage divider and current limiting branch is connected to the signal output terminal of the input interface channel, and is used to divide and limit the input sensor signal before outputting it to the positive input terminal of the comparator amplifier circuit. The reference level branch is connected to the signal output terminal of the input interface channel, and is used to provide a reference level after dividing the input sensor signal to achieve dynamic matching and filtering of signal amplitude.

8. The system according to claim 3, characterized in that, The comparison amplifier circuit includes an operational amplifier, a first resistor, a second resistor, and a feedback resistor. The positive input terminal of the operational amplifier is connected to the output terminal of the first voltage divider and current limiting branch. The negative input terminal is connected to a reference voltage through the first resistor and grounded through the second resistor. The output terminal is connected to the positive input terminal through the feedback resistor to form a hysteresis characteristic. The operational amplifier is used to compare the voltage-divided and current-limited sensor signal input at the positive input terminal with the reference voltage at the negative input terminal. When the voltage amplitude of the sensor signal exceeds the comparison threshold, the output terminal outputs a flip signal.

9. The system according to claim 3, characterized in that, The synchronization pulse output module includes a third resistor, one end of which is connected to the output terminal of the operational amplifier, and the other end is used to connect to the input pin of an external controller. The synchronization pulse output module is used to convert the flip signal output by the operational amplifier into a synchronization pulse signal and transmit it to the external controller so that the external controller can capture the communication beat of the sensor signal or realize data synchronization.

10. The system according to claim 1, characterized in that, The script control module includes a collision curve editing submodule, which supports importing acceleration time-domain curve data from real vehicle collision tests.

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