Hybrid agricultural machine functional safety protection test device and test method

Abstract

The application relates to a hybrid agricultural machine function safety protection test device and a test method, the device comprising: a plurality of action sensors, respectively installed on the accelerator pedal, the brake pedal, the wheel hub, the door and the gear lever of the measured agricultural machine, used for collecting the motion state data of the measured components and transmitting through a wireless network; an industrial camera used for collecting instrument table images; an instruction indicating screen used for displaying test operation instructions to the driver; a test host machine in communication connection with the industrial camera, the instruction indicating screen and each action sensor; the test host machine sends operation instructions to the driver through the instruction indicating screen according to a preset function safety test program, receives and analyzes the data collected by the action sensors and the industrial camera, automatically judges the test results of each function safety test through interaction with the vehicle and saves the test data. The application greatly simplifies the hybrid agricultural machine function safety protection test process and improves the test efficiency.

Description

Technical Field

[0001] This invention belongs to the field of functional safety protection testing technology for hybrid agricultural machinery, specifically relating to a functional safety protection testing device and testing method for hybrid agricultural machinery. Background Technology

[0002] Before hybrid agricultural machinery can be marketed, it must undergo functional safety protection testing. According to the relevant provisions of the national standard GB 18384-2020, the functional safety protection test items mainly include the drive system power on / off procedure, power reduction warning, REESS low battery warning, REESS thermal event alarm, braking priority, driving gear switching, reverse driving, and vehicle-to-external conductive connection locking tests. Currently, these tests are manually verified by technicians, without dedicated testing equipment, resulting in low testing efficiency and a lack of objective test data to support the evaluation of test results. Summary of the Invention

[0003] The purpose of this invention is to provide a functional safety protection testing device and testing method for hybrid agricultural machinery. The device is easy to install and simple to use. During testing, the driver only needs to operate the vehicle according to the on-screen prompts. The device can automatically evaluate the results and automatically save all objective test data of the whole vehicle testing process.

[0004] To achieve the above objectives, the technical solution adopted by the present invention is: a functional safety protection testing device for hybrid agricultural machinery, comprising: Multiple motion sensors are installed on the accelerator pedal, brake pedal, wheel hub, door, and gear shift lever of the agricultural machinery under test. Each motion sensor has a built-in inertial measurement unit and magnetometer to collect motion state data of the tested components and transmit it through a wireless network. An industrial camera, installed in the driver's cab, is used to capture images of the dashboard; The instruction display screen is installed in a visible position inside the driver's cab and is used to display test operation instructions to the driver; The test host is connected to the industrial camera and the instruction display screen, and communicates wirelessly with each motion sensor. According to the preset functional safety test program, the test host issues operation instructions to the driver through the instruction display screen, receives and analyzes the data collected by the motion sensors and the industrial camera, and automatically judges the test results of each functional safety test and saves the test data through interaction with the vehicle.

[0005] Furthermore, the motion sensors include an accelerator pedal motion sensor, a brake pedal motion sensor, a wheel motion sensor, a door motion sensor, and a gear position motion sensor; the housings of all motion sensors are marked with the directions of the three coordinate axes of the coordinate system.

[0006] Furthermore, the accelerator pedal action sensor and the brake pedal action sensor are respectively fixed to the lower surface of the accelerator pedal and the brake pedal, and the Z-axis of the accelerator pedal action sensor and the brake pedal action sensor is perpendicular to the pedal and points to the floor, the X-axis points to the vehicle's forward direction, and the Y-axis points to the right side of the vehicle. The wheel motion sensor is fixed to the center of the wheel hub, with its Z-axis pointing towards the wheel axis. The door motion sensor is fixed to the door, with its X-axis pointing in the direction of vehicle movement, its Y-axis pointing vertically downwards, and its Z-axis pointing inwards. The gear position sensor is fixed to the upper surface of the gear shift lever. Its Z-axis is parallel to the gear shift lever and points to the floor, its X-axis points to the direction of vehicle movement, and its Y-axis points to the right side of the vehicle.

[0007] Furthermore, the motion sensor includes a wireless master control module, an IMU chip, and a magnetometer chip; the IMU chip is used to collect the triaxial acceleration and triaxial angular velocity of the object under test and send the raw data to the wireless master control module; the magnetometer chip is used to collect the triaxial magnetic force values ​​around the object under test and send the raw data to the wireless master control module; the wireless master control module parses the received data and sends it to the test host.

[0008] Furthermore, the test host internally includes a main control chip, a USB interface, a serial screen interface, a WIFI module, a microphone, an audio conditioning chip, a CAN connection terminal, a CAN transceiver chip, a host power supply connection terminal, and a host power supply unit. The industrial camera sends image information to the main control chip via the USB interface; the instruction indicator screen communicates with the main control chip via the serial screen interface; test data from the motion sensor is received via the WIFI module and directly transmitted to the main control chip; the test host collects sound signals via the microphone, processes them through the audio conditioning chip, and sends them to the main control chip; the automotive OBD interface communicates with the main control chip via the CAN connection terminal and the CAN transceiver chip; and the power supply provides power to each module and chip via the host power supply connection terminal and the host power supply unit.

[0009] Based on the testing device, this invention further proposes a functional safety protection testing method for hybrid agricultural machinery. This method utilizes the aforementioned functional safety protection testing device and includes the following steps: S1, install multiple wireless motion sensors on the accelerator pedal, brake pedal, wheel hub, door and gear shift lever of the agricultural machine under test, and install an industrial camera, instruction display screen and test host in a designated position in the cab, and connect the test host with the vehicle. S2, after the vehicle starts, the test host is powered on, and each wireless motion sensor performs initial self-calibration and records the initial attitude information. S3, the test host issues operation instructions to the driver through the instruction display screen according to the selected functional safety test items; S4, the test host receives and analyzes the data collected during the test in real time and interacts with the vehicle; S5: The test host automatically determines the test result of the current test item according to the preset judgment logic and saves all test data.

[0010] Furthermore, the functional safety test items include: (1) drive system power on and off procedure; (2) driving gear switching; (3) power reduction warning; (4) REESS low battery warning; (5) REESS thermal event alarm; (6) brake priority; (7) reverse driving; (8) vehicle and external conductive connection lock.

[0011] Furthermore, the following steps are included in the test procedures for power on / off of the drive system and gear shifting: S1, the vehicle is powered on, and the driver selects the test item on the instruction display screen; following the prompts on the instruction display screen, the driver does not press the brake pedal and engages a gear. The test host starts the test program when it detects the gear shift lever movement through the gear position sensor; S2, the driver presses the accelerator pedal as prompted by the instruction display screen: When the test host detects wheel hub rotation through the wheel motion sensor, it determines that the test result has failed and terminates the test program. If the test host does not detect wheel hub rotation, the test is deemed qualified and proceeds to the next step; S3, the driver presses the brake pedal according to the instruction display screen and shifts gears again. At this time, the test host detects that the brake pedal is pressed through the brake pedal action sensor, and the test program starts the next test. S4, the driver presses the accelerator pedal according to the instructions on the command display screen: When the test host detects wheel hub rotation through the wheel motion sensor, it determines that the driving gear switching test result is qualified and proceeds to the next test process; If the test host does not detect wheel hub rotation, the driving gear switching test result is determined to be a failure, and the test program ends. S5, the driver keeps the car in gear as prompted by the instruction display screen and opens the door. At this time, the test host detects the door opening through the door motion sensor and the test program enters the next test process. S6, wait for the preset data acquisition time. If the test host detects an alarm light on the instrument panel through the industrial camera, or detects an alarm sound through the acquired sound signal, the test result of the drive system power on / off program test is deemed qualified; otherwise, it is deemed unqualified.

[0012] Further, when conducting power reduction prompt, REESS low battery prompt, and REESS thermal event alarm test, the following steps are included: S1. Power on the vehicle. The driver selects the corresponding test item on the command display screen and drives the vehicle normally. S2. After a preset time from the start of the test, the test host injects the corresponding low power message, low battery message, or high temperature message into the vehicle through the vehicle OBD interface. S3. Wait for the preset data acquisition time. If the test host detects that the warning light on the instrument panel lights up through the industrial camera, or detects a warning sound through the collected sound signal, it is determined that the corresponding test is qualified; otherwise, it is unqualified.

[0013] Further, when conducting the brake priority test, the following steps are included: S1. Power on the vehicle. The driver selects the test item on the command display screen, steps on the brake pedal and gears up. The test host starts the test after detecting that the brake pedal is stepped on through the brake pedal movement sensor. S2. Step on the accelerator pedal and the brake pedal simultaneously according to the prompt on the command display screen. S3. Wait for the preset data acquisition time. If the test host does not detect the movement of the wheel movement sensor, it is determined that the test result is qualified; otherwise, it is unqualified.

[0014] Further, when conducting the reverse driving test, the following steps are included: S1. Power on the vehicle. The driver selects the test item on the command display screen and inputs the wheel rolling radius and the vehicle speed threshold for allowing reverse gear engagement during driving. S2. The driver steps on the brake pedal and gears up and drives normally. S3. The driver steps on the accelerator pedal. The test host starts the test after detecting the vehicle driving through the wheel movement sensor and calculates the driving vehicle speed based on the angular velocity around the Z-axis and the rolling radius. S4. When the driving vehicle speed exceeds the vehicle speed threshold, the command display screen prompts the driver to engage the reverse gear. After the driver engages the reverse gear, the test host detects the movement of the shift lever through the gear position movement sensor and starts recording test data. S5. Within the preset recording time, determine whether the test result is qualified according to the positive and negative values of the Z-axis angular velocity of the wheel movement sensor.

[0015] Further, when conducting the vehicle and external conduction connection locking test, the following steps are included: S1. Insert the charging gun into the vehicle and power on. The driver selects the test item on the command display screen. S2. The driver steps on the brake pedal and gears up. The test host starts the test after detecting that the brake pedal is stepped on through the brake pedal movement sensor. S3. Step on the accelerator pedal according to the prompt on the command display screen. The test host starts recording test data after detecting the movement of the accelerator pedal through the accelerator pedal movement sensor. S4. After reaching the preset time, the test host checks whether the wheel movement sensor has moved. If it has moved, it is determined that the test result is unqualified.

[0016] Furthermore, the functional safety protection testing method can be used for both indoor and outdoor testing; when testing indoors, the vehicle under test is placed on a dynamometer.

[0017] The beneficial effects of this invention are: the testing device proposed in this invention is simple in composition, low in cost, easy to install, and convenient to use. During testing, after starting the vehicle and waiting 10 seconds for power-on, the sensor self-calibration is completed. The driver can then follow the on-screen prompts to complete the corresponding test. All test results are automatically determined based on the collected data, without the need for technical personnel confirmation, and the test results are traceable. Therefore, it can greatly simplify the functional safety protection testing process of hybrid agricultural machinery, improve testing efficiency, and the device can be used for testing both indoors and outdoors, unaffected by the test site. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structural composition of the hybrid agricultural machinery functional safety protection testing device proposed in this invention; Figure 2 This is a schematic diagram of the motion sensor in this invention; Figure 3 This is a schematic diagram of the structure of the test host in this invention; Figure 4 This is a schematic diagram of the coordinate system after the accelerator pedal action sensor of the present invention has been installed; Figure 5 This is a schematic diagram of the coordinate system after the door motion sensor of the present invention has been installed; Figure 6 This is a schematic diagram of the coordinate system after the wheel motion sensor of the present invention has been installed; Figure 7 This is a schematic diagram of the coordinate system after the gear position action sensor of the present invention has been installed; The diagram shows the following components: 1. Agricultural machinery under test; 2. Accelerator pedal; 3. Accelerator pedal motion sensor; 4. Brake pedal; 5. Brake pedal motion sensor; 6. Wheel hub; 7. Wheel motion sensor; 8. Door; 9. Door motion sensor; 10. Gear shift lever; 11. Gear position motion sensor; 12. Industrial camera; 13. Command indicator screen; 14. Test host; 15. Wireless main control module; 16. IMU chip; 17. Magnetometer chip; 18. Power supply unit; 19. Lithium battery; 20. Lithium battery management unit; 21. Power supply connection terminal; 22. Main control chip; 23. USB interface; 24. Serial screen interface; 25. WIFI module; 26. Microphone; 27. Audio conditioning chip; 28. CAN connection terminal; 29. ​​CAN transceiver chip; 30. Host power supply connection terminal; 31. Host power supply unit. Detailed Implementation

[0019] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments, but this should not be construed as limiting the invention in any way.

[0020] See attached document Figure 1 As shown, the functional safety protection test device for hybrid agricultural machinery proposed in this invention mainly consists of an accelerator pedal action sensor 3, a brake pedal action sensor 5, a wheel action sensor 7, a door action sensor 9, a gear action sensor 11, an industrial camera 12, an instruction display screen 13, and a test host 14.

[0021] The accelerator pedal motion sensor 3 is fixed to the lower surface of the accelerator pedal 2 by adhesive or other means, and the brake pedal motion sensor 5 is fixed to the lower surface of the brake pedal 4 by adhesive or other means, so as not to affect the pressing of the accelerator pedal 2 and the brake pedal 4. The wheel motion sensor 7 is attached to the center of the wheel hub 6, the door motion sensor 9 is attached to the surface of the door 8, and the gear position motion sensor 11 is attached to the upper surface of the gear shift lever 10, avoiding the hand grip area of ​​the gear shift lever 10. The industrial camera 12 is fixed inside the vehicle and records video facing the dashboard. The instruction display screen 13 is fixed inside the vehicle to display operation information. The test host 14 is placed inside the vehicle, with a built-in TCP server and a WIFI hotspot; the accelerator pedal motion sensor 3, brake pedal motion sensor 5, wheel motion sensor 7, door motion sensor 9, and gear position motion sensor 11 are connected to the test host 14 via WIFI, and then connected to the TCP server of the test host 14 for transmitting test data.

[0022] The accelerator pedal action sensor 3, brake pedal action sensor 5, wheel action sensor 7, door action sensor 9, and gear position action sensor 11 are collectively referred to as action sensors and have the same structure. The following is a combination of... Figure 2 The structure and operation of the motion sensor are described below. The motion sensor includes a wireless main control module 15, an IMU chip 16, a magnetometer chip 17, a power supply unit 18, a lithium battery 19, a lithium battery management unit 20, and a power supply connection terminal 21. The IMU chip 16, as an inertial measurement unit, collects the triaxial acceleration and triaxial angular velocity of the measured object and sends the raw data to the wireless main control module 15. The magnetometer chip 17, as a magnetometer, collects the triaxial magnetic force values ​​around the measured object and sends the raw data to the wireless main control module 15. The lithium battery 19 supplies power to the power supply unit 18, which then distributes the voltage to the various modules and chips. When the lithium battery 19 is depleted, a charging device such as a mobile phone charger can be plugged into the power supply connection terminal 21, and the current will flow through the lithium battery management unit 20 to charge the lithium battery 19. All motion sensor housings are marked with the three coordinate axes of the coordinate system.

[0023] The operation of the aforementioned motion sensor is as follows: the IMU chip 16 collects the acceleration of the object under test along the XYZ axes and the angular velocity of its rotation around the XYZ axes and sends them to the wireless main control module 15; the magnetometer chip 17 collects the three-axis magnetic force values ​​at the location of the object under test and sends them to the wireless main control module 15. After the system is powered on, the wireless main control module 15 continuously reads the three-axis acceleration and three-axis angular velocity of the object under test, and calculates the roll angle around the X-axis and the pitch angle around the Y-axis of the object under test in its initial state using the three-axis acceleration. At the same time, the main control module 15 continuously reads the three-axis magnetic force values ​​of the object under test, and calculates the true magnetic field direction and magnitude at the location of the object under test by comparing them with the initial roll angle and pitch angle. As the test object moves, three attitude angles can be continuously acquired through triaxial angular velocity integration. Then, triaxial acceleration is used with Kalman filtering to compensate for accumulated errors in the attitude angles, obtaining accurate roll and pitch angles. The roll and pitch angles are calculated using the actual magnetic field value at the test object's location to predict the heading angle around the Z-axis. This predicted heading angle is then combined with the heading angle obtained through angular velocity integration and Kalman filtering to finally measure the stable attitude angles of the test object. The wireless master control module 15 packages the triaxial acceleration, triaxial angular velocity, triaxial magnetic field values, and three attitude angles into a data packet. Once the wireless master control module 15 connects to the TCP server of the test host 14 via WIFI, it sends the packaged data to the test host 14.

[0024] The structural composition of the test host 14 is as follows: Figure 3 As shown, the system mainly consists of a main control chip 22, a USB interface 23, a serial screen interface 24, a WIFI module 25, a microphone 26, an audio conditioning chip 27, a CAN connection terminal 28, a CAN transceiver chip 29, a host power supply connection terminal 30, and a host power supply unit 31. The industrial camera 12 sends image information to the main control chip 22 via the USB interface 23; the instruction indicator screen 13 communicates with the main control chip 22 via the serial screen interface 24; test data from various motion sensors is received via the WIFI module 25 and directly transmitted to the main control chip 22; the test host 14 collects sound signals via the microphone 26, processes them via the audio conditioning chip 27, and sends them to the main control chip 22; the automotive OBD interface communicates with the main control chip 22 via the CAN connection terminal 28 and the CAN transceiver chip 29; and power is supplied to each module and chip via the host power supply connection terminal 30 and the host power supply unit 31.

[0025] The working process of the test host 14 receiving motion sensor test data is as follows: The WIFI module 25 in the test host 14 can work in WIFI host mode and provide WIFI connection service. All motion sensors can connect to the WIFI module 25 via WIFI. The WIFI module 25 has a built-in TCP server that provides connection service. After all motion sensors are connected to WIFI, they can connect to the TCP server. The TCP server receives the data from the motion sensors and forwards it to the main control chip 22. The main control chip 22 performs different logical processing based on the received motion sensor data to determine the triggering of the action.

[0026] The installation method of the hybrid agricultural machinery functional safety protection testing device of the present invention is as follows: Step 1: The industrial camera 12 is fixed inside the vehicle and connected to the test host 14 via the USB interface 23, ensuring that the lens of the industrial camera 12 is facing the agricultural machinery dashboard for acquiring dashboard images. Step 2: Connect the CAN connection terminal 28 of the test host 14 to the vehicle's OBD interface; Step 3: Connect the instruction display screen 13 to the serial screen interface 24 of the test host 14; Step four, as Figure 1 As shown, the vehicle's coordinate system is defined with the X-axis as the vehicle's forward direction, the Z-axis perpendicular to the X-axis and pointing vertically downwards, and the Y-axis perpendicular to the XZ plane and pointing to the right of the vehicle. Step 5: Attach the accelerator pedal action sensor 3 and brake pedal action sensor 5 to the bottom of the accelerator pedal 2 and brake pedal 4, respectively. Taking the installation of the accelerator pedal action sensor 3 as an example, during installation, the coordinate axis direction of the housing needs to be adjusted so that the Z-axis is perpendicular to the pedal and points directly to the vehicle floor, the X-axis points in the direction of vehicle movement, and the Y-axis points to the right side of the vehicle. Figure 4 As shown; the installation of brake pedal action sensor 5 is the same as that of accelerator pedal action sensor 3. Step six: The wheel motion sensor 7 is attached to the center of the wheel hub 6, with the X-axis pointing in the direction of vehicle movement, the Y-axis pointing to the ground, and the Z-axis pointing to the wheel axle. Figure 5 As shown; Step 7: The door motion sensor 9 is attached to the door 8, with the X-axis pointing in the direction of vehicle movement, the Y-axis pointing to the ground, and the Z-axis perpendicular to the XY plane and pointing inwards. Figure 6 As shown; Step 8: The gear shift sensor 11 is attached to the upper surface of the gear shift lever 10. The X-axis points in the vehicle's forward direction, the Z-axis is parallel to the gear shift lever and points towards the vehicle floor, and the Y-axis is perpendicular to the XZ plane and points to the right of the vehicle. Figure 7 As shown; Step 9: After installation, start the tractor and maintain idle speed. After the test host 14 is powered on, wait 10 seconds. The accelerator pedal action sensor 3, brake pedal action sensor 5, wheel action sensor 7, door action sensor 9, and gear action sensor 11 will automatically calculate the sensor error and record the initial posture information.

[0027] The detection process for the accelerator pedal 2 being depressed is as follows: When the accelerator pedal 2 is depressed, the Z-axis acceleration and the resolved pitch angle of the accelerator pedal action sensor 3 will change drastically. The main control chip 22 in the test host 14 can set action thresholds and monitor them in real time. When both the Z-axis acceleration and pitch angle reach the set thresholds, it is determined that the accelerator pedal 2 has been depressed. The detection process for the brake pedal 4 is the same as that for the accelerator pedal 2.

[0028] The detection process for the rotation of the wheel hub 6 is as follows: When the wheel hub 6 rotates, the angular velocity around the Z-axis of the wheel motion sensor 7 changes drastically. The main control chip 22 in the test host 14 can set an action threshold and monitor it in real time. When the angular velocity around the Z-axis reaches the set threshold, it is determined that the wheel is rotating. Simultaneously, when the vehicle is moving forward, the angular velocity reading around the Z-axis is defined as positive, and when the vehicle is reversing, the angular velocity reading around the Z-axis is defined as negative. Therefore, by determining the sign of the angular velocity around the Z-axis, it is possible to detect whether the vehicle is moving forward or backward. The main control chip 22 can also calculate the vehicle's speed from the angular velocity around the Z-axis and the tire rolling radius. In other embodiments, a negative angular velocity reading around the Z-axis can be defined as forward movement, and a positive reading as reverse movement.

[0029] The detection process of the door 8 opening action is as follows: when the door 8 opens, the Z-axis acceleration and the resolved pitch angle of the door action sensor 9 will change drastically. The main control chip 22 in the test host 14 can set the action threshold and monitor it in real time. When the Z-axis acceleration and pitch angle both reach the set threshold, it is determined that the door 8 has performed the opening action.

[0030] The detection process of the shift lever 10 shifting action is as follows: when the shift lever 10 shifts gears, the X-axis acceleration or Y-axis acceleration of the gear position action sensor 11 and the resolved pitch angle and roll angle will change drastically. The main control chip 22 in the test host 14 can set the action threshold and monitor it in real time. When the X-axis acceleration and pitch angle both reach the threshold or the Y-axis acceleration and roll angle both reach the set threshold, it is determined that the shift lever 10 has performed a shifting action.

[0031] Example 2 A method for testing the functional safety protection of hybrid agricultural machinery, using the testing device described in Example 1, includes the following steps: S1. According to the installation specifications described in Example 1, multiple wireless motion sensors are installed on the accelerator pedal, brake pedal, wheel hub, door and gear shift lever of the agricultural machine under test, and the industrial camera 12, instruction display screen 13 and test host 14 are installed in the designated position in the cab. The CAN connection terminal 28 of the test host 14 is connected to the vehicle OBD interface. S2, after the vehicle starts, the test host 14 is powered on, and each wireless motion sensor performs initial self-calibration and records the initial attitude information. S3, the test host 14 issues operation instructions to the driver through the instruction display 13 according to the selected functional safety test items; S4, the test host 14 receives and analyzes the data collected by each wireless motion sensor, industrial camera 12 and sound acquisition module in real time, and interacts with the vehicle through the CAN communication module; S5, the test host 14 automatically judges the test result of the current test item according to the preset judgment logic, and saves all test data.

[0032] The functional safety test items include: (1) drive system power on / off procedure; (2) driving gear switching; (3) power reduction warning; (4) REESS low battery warning; (5) REESS thermal event alarm; (6) brake priority; (7) reverse driving; (8) vehicle-to-external conductive connection locking. The judgment criteria for the results of various test items comply with the relevant provisions of national standard GB18384-2020.

[0033] The automated determination of the functional safety test items during testing relies on the following three general testing methods, which are automatically executed by the main control chip of the test host.

[0034] (1) Instrument panel alarm light detection: The test host 14 acquires real-time images of the instrument panel through the industrial camera 12, and automatically identifies the alarm light status using the following steps: Step 1: The industrial camera 12 is installed inside the vehicle, with the lens facing the driver's dashboard to capture images, and the captured images are sent to the main control chip 22 of the test host 14 via the USB interface 23. Step 2: The main control chip 22 divides the image into 50×100 regions, or adjusts the number of regions to be divided according to the experimental requirements; Step 3: Convert the image of each region to grayscale; Step 4: Calculate the average brightness of each area and store 5000 brightness values ​​in real time; Step 5: Compare the brightness values ​​of 5000 areas with the brightness values ​​of the previous moment. When the brightness change of any area exceeds the set threshold, it is determined that an indicator light is on. This detection method does not require image training, has low computational load, and is suitable for detecting the lighting of dashboard indicator lights.

[0035] (2) Vehicle alarm sound detection: The test host 14 collects the sound signal in the driver's cab in real time through the microphone 26, and automatically identifies the alarm sound status using the following steps: Step 1: The microphone 26 in the test host 14 collects the ambient sound pressure value, converts it into a digital signal through the audio conditioning chip 27, and transmits it to the main control chip 22. Step 2: The main control chip 22 performs an FFT transformation every 100ms to calculate and store the amplitude of 1 / 3 octave band in the 500-20000Hz frequency band. Step 3: Calculate the difference between the amplitude of each 1 / 3 octave band and the amplitude at the previous moment. When the amplitude change of any frequency band exceeds the set threshold, an alarm is detected. This detection method is suitable for both continuous alarm detection and intermittent alarm detection.

[0036] (3) Testing the injection of fault messages into the vehicle: The test host 14 injects fault messages into the vehicle through the CAN communication module to simulate a fault state and trigger the vehicle alarm function. The test steps are as follows: Step 1: Select the test item to be performed via the instruction display screen 13; Step 2: 30 seconds after the test starts (or other preset time), the main control chip 22 sends the message to the CAN transceiver chip 29. The CAN transceiver chip 29 processes the message into a differential signal and then sends it to the agricultural machine under test 1 via the CAN connection terminal 28. Step 3: After message injection, the test host 14 immediately starts data acquisition to monitor the vehicle's alarm response.

[0037] This method allows for safe and repeatable testing of a vehicle's alarm functions without actually creating dangerous malfunctions. The pre-set fault messages in the test host 14 include, but are not limited to: low power message, low battery message, and high temperature message.

[0038] The specific test methods for the above test items are explained in detail below. Test (1) and Test (2) are completed in the same test process; Test (3), Test (4) and Test (5) are completed in the same test process.

[0039] 1. The test methods for the "Drive System Power On / Off Procedure" and "Gear Shifting" tests are as follows: Step 1: Power on the vehicle. The driver selects this test on the instruction display screen 13 and, according to the prompts on the instruction display screen 13, does not step on the brake pedal 4 and shifts gears. At this time, when the test host 14 detects the movement of the shift lever 10 through the gear position movement sensor 11, the test program is started; Step 2: The driver steps on the accelerator pedal 2 according to the prompts on the instruction display screen 13: (1) When the test host 14 detects the rotation of the wheel hub 6 through the wheel movement sensor 7, it is determined that the test result is failed and the test program ends; (2) When the test host 14 does not detect the rotation of the wheel hub 6, it is determined that the test is qualified and proceeds to the next step; Step 3: The driver steps on the brake pedal 4 according to the prompts on the instruction display screen 13 and shifts gears again. At this time, when the test host 14 detects that the brake pedal 4 is stepped on through the brake pedal movement sensor 5, the test program starts the next test; Step 4: The driver steps on the accelerator pedal 2 according to the prompts on the instruction display screen 13: (1) When the test host 14 detects the rotation of the wheel hub 6 through the wheel movement sensor 7, it is determined that the "drive gear shift" test result is qualified and proceeds to the next test process; (2) When the test host (14) does not detect the rotation of the wheel hub (6), it is determined that the drive gear shift test fails and the test program ends; Step 5: The driver keeps the gear engaged according to the prompts on the instruction display screen 13 and opens the door 8. At this time, when the test host 14 detects that the door 8 is opened through the door movement sensor 9, the test program proceeds to the next test process; Step 6: Wait for 10s for data acquisition time (or other preset data acquisition time). If the test host 14 detects that the warning light on the instrument panel is on through the industrial camera 12 or detects an alarm sound through the microphone 26, it is determined that the "drive system power on and off procedure" test result is qualified. Otherwise, it is determined that the "drive system power on and off procedure" test is unqualified.

[0040] 2. The test methods for "power reduction prompt", "REESS low battery prompt", and "REESS thermal event alarm" are as follows: Step 1: Power on the vehicle. The driver selects the corresponding test on the instruction display screen 13 and drives the vehicle normally; Step 2: After 30s (or other preset time) from the start of the test, the test host 14 injects one of the following three messages into the vehicle through the CAN connection terminal 28: power low message, low battery message, high temperature message, and starts data acquisition; Step 3: Wait for 10s for data acquisition time (or other preset data acquisition time). If the test host 14 detects that the warning light on the instrument panel is on through the industrial camera 12 or detects an alarm sound through the microphone 26, it is determined that the corresponding test is qualified, otherwise it is unqualified.

[0041] 3. The test method for "brake priority" is as follows: Step 1: Power on the vehicle. The driver selects this test on the instruction display screen 13, presses the brake pedal 4 and engages the gear. At this time, the test host 14 detects that the brake pedal 4 is pressed through the brake pedal action sensor 5, and the test program starts. Step 2: The driver simultaneously presses the accelerator pedal 2 and the brake pedal 4 as prompted by the instruction display screen 13; Step 3: Wait 30 seconds for data acquisition (or other preset data acquisition time). If the test host 14 does not detect the wheel motion sensor 7, the test result is considered qualified; otherwise, it is considered unqualified.

[0042] 4. The test method for the "reverse driving" test is as follows: Step 1: Power on the vehicle. The driver selects this test on the instruction display screen 13 and inputs the wheel rolling radius and the vehicle speed threshold that allows the vehicle to engage reverse gear while driving through the instruction display screen 13. Step 2: The driver depresses the brake pedal and engages gear to drive normally; Step 3: The driver presses the accelerator pedal 2. At this time, the test host 14 detects the vehicle movement through the wheel motion sensor 7 and the test program is started. At this time, the test host 14 can also calculate the vehicle speed by multiplying the Z-axis angular velocity and the rolling radius. Step 4: When the vehicle speed exceeds the speed threshold for shifting gears, the instruction display screen 13 prompts the driver to engage reverse gear. After the driver engages reverse gear, the test host 14 detects the movement of the gear shift lever 10 through the gear position action sensor 11 and begins data recording. Step 5: Record test data continuously for 10 seconds (or other preset data acquisition time). If the Z-axis angular velocity of the wheel motion sensor 7 becomes negative, it indicates that the vehicle has started to reverse, and the test result is deemed unqualified. If the Z-axis angular velocity of the wheel motion sensor 7 is positive, it indicates that reversing is not allowed, and the test result is deemed qualified.

[0043] It should be noted that the vehicle's forward or backward driving state can be determined by the positive or negative value of the Z-axis angular velocity. The wheel motion sensor 7 can be customized. In other embodiments, a negative Z-axis angular velocity can be determined as the vehicle moving forward, while a positive Z-axis angular velocity can be determined as the vehicle moving backward.

[0044] The test method for "vehicle-external conductive connection locking" is as follows: Step 1: Connect the charging gun to the vehicle, power on the vehicle, and the driver selects this test on the instruction display screen 13; Step 2: The driver presses the brake pedal 4 and engages gear. At this time, the test host 14 detects that the brake pedal 4 is pressed through the brake pedal action sensor 5, and the test program is started. Step 3: The driver presses the accelerator pedal 2 according to the prompts on the instruction display screen 13. At this time, the test host 14 detects the action of the accelerator pedal 2 through the accelerator pedal action sensor 3 and begins to record test data. Step 4: After continuously recording data for 10 seconds (or other preset data acquisition time), if the test host 14 does not detect any action of the wheel motion sensor 7, the test result is qualified; otherwise, the test result is deemed unqualified.

[0045] All the above tests can be conducted outdoors or indoors. When testing indoors, the vehicle should be parked on the dynamometer.

[0046] The above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Those skilled in the art should understand that modifications or equivalent substitutions can be made to the specific implementation of the present invention with reference to the above embodiments. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention are within the protection scope of the pending claims.

Claims

1. A functional safety protection testing device for hybrid agricultural machinery, characterized in that, include: Multiple motion sensors are installed on the accelerator pedal (2), brake pedal (4), wheel hub (6), door (8) and gear shift lever (10) of the agricultural machinery under test (1), respectively. Each motion sensor has a built-in inertial measurement unit and magnetometer to collect motion state data of the tested parts and transmit it through a wireless network. An industrial camera (12) is installed in the cab to capture images of the dashboard; The instruction display screen (13) is installed in a visible position in the cab and is used to display test operation instructions to the driver; The test host (14) is connected to the industrial camera (12) and the instruction display screen (13) respectively, and communicates wirelessly with each motion sensor. The test host (14) issues operation instructions to the driver through the instruction display screen (13) according to the preset functional safety test program, receives and analyzes the data collected by the motion sensor and the industrial camera (12), and automatically judges the test results of each functional safety test and saves the test data by interacting with the vehicle.

2. The functional safety protection testing device according to claim 1, characterized in that: The motion sensors include an accelerator pedal motion sensor (3), a brake pedal motion sensor (5), a wheel motion sensor (7), a door motion sensor (9), and a gear position motion sensor (11); the housings of all motion sensors are marked with the directions of the three coordinate axes of the coordinate system.

3. The functional safety protection testing device according to claim 2, characterized in that: The accelerator pedal action sensor (3) and brake pedal action sensor (5) are respectively fixed on the lower surface of the accelerator pedal (3) and brake pedal (5), and the Z-axis of the accelerator pedal action sensor (3) and brake pedal action sensor (5) is perpendicular to the pedal and points to the floor, the X-axis points to the direction of vehicle movement, and the Y-axis points to the right side of the vehicle. The wheel motion sensor (7) is fixed to the center of the wheel hub (6), and its Z-axis points to the wheel axis. The door motion sensor (9) is fixed on the door (8), with its X-axis pointing in the direction of vehicle movement, its Y-axis pointing vertically downward, and its Z-axis pointing inward. The gear position sensor (11) is fixed on the upper surface of the gear shift lever (10). Its Z-axis is parallel to the gear shift lever (10) and points to the floor, its X-axis points to the direction of vehicle movement, and its Y-axis points to the right side of the vehicle.

4. The functional safety protection testing device according to claim 2, characterized in that: The motion sensor includes a wireless main control module (15), an IMU chip (16), and a magnetometer chip (17); the IMU chip (16) is used to collect the triaxial acceleration and triaxial angular velocity of the object under test and send the raw data to the wireless main control module (15); the magnetometer chip (17) is used to collect the triaxial magnetic force value around the object under test and send the raw data to the wireless main control module (15); the wireless main control module (15) parses the received data and sends it to the test host (14).

5. The functional safety protection testing device according to claim 3, characterized in that: The test host (14) is equipped with a main control chip (22), a USB interface (23), a serial screen interface (24), a WIFI module (25), a microphone (26), an audio conditioning chip (27), a CAN connection terminal (28), a CAN transceiver chip (29), a host power supply connection terminal (30), and a host power supply unit (31); the industrial camera (12) sends image information to the main control chip (22) through the USB interface (23); the instruction display (13) connects to the main control chip (22) through the serial screen interface (24). The control chip (22) communicates; the test data of the motion sensor is received through the WIFI module (25) and directly transmitted to the main control chip (22); the test host (14) collects sound signals through the microphone (26), processes them through the audio conditioning chip (27) and sends them to the main control chip (22); the car OBD interface communicates with the main control chip (22) through the CAN connection terminal (28) and the CAN transceiver chip (29); the power supply provides power to each module and chip through the host power supply connection terminal (30) and the host power supply unit (31).

6. A method for testing the functional safety protection of hybrid agricultural machinery, characterized in that: This method uses the functional safety protection testing device according to any one of claims 1-5, and includes the following steps: S1, install multiple wireless motion sensors on the accelerator pedal (2), brake pedal (4), wheel hub (6), door (8) and gear shift lever (10) of the agricultural machine under test (1), and install the industrial camera (12), instruction display screen (13) and test host (14) in the designated position in the cab, and connect the test host with the vehicle. S2, after the vehicle starts, the test host (14) is powered on, and each wireless motion sensor performs initial self-calibration and records the initial posture information; S3, the test host (14) issues operation instructions to the driver through the instruction display (13) according to the selected functional safety test items; S4, the test host (14) receives and analyzes the data collected during the test in real time and interacts with the vehicle; S5, the test host (14) automatically judges the test result of the current test item according to the preset judgment logic and saves all test data.

7. The functional safety protection test method according to claim 6, characterized in that: The functional safety test items include: (1) drive system power on and off procedure; (2) driving gear switching; (3) power reduction warning; (4) REESS low battery warning; (5) REESS thermal event alarm; (6) brake priority; (7) reverse driving; (8) vehicle and external conductive connection lock.

8. The functional safety protection test method according to claim 7, characterized in that: The following steps are included in the test procedures for power on / off of the drive system and gear shifting: S1, the vehicle is powered on, and the driver selects the test item on the instruction display screen (13); according to the prompt of the instruction display screen (13), the driver does not step on the brake pedal (4) and shifts into gear. When the test host (14) detects the shift lever (10) moving through the gear position action sensor (11), the test program is started. S2, the driver presses the accelerator pedal (2) according to the prompt on the instruction display screen (13): When the test host (14) detects the rotation of the wheel hub (6) through the wheel motion sensor (7), the test result is determined to be unsuccessful and the test program ends. If the test host (14) does not detect the rotation of the hub (6), the test is deemed to be qualified and proceeds to the next step; S3, the driver presses the brake pedal (4) according to the instruction display (13) and re-engages the gear. At this time, the test host (14) detects that the brake pedal (4) is pressed through the brake pedal action sensor (5), and the test program starts the next test. S4, the driver presses the accelerator pedal (2) according to the prompt on the instruction display screen (13): When the test host (14) detects the rotation of the wheel hub (6) through the wheel motion sensor (7), it determines that the driving gear switching test result is qualified and enters the next test process; When the test host (14) does not detect the rotation of the wheel hub (6), the test result of the driving gear switching test is determined to be a failure and the test program ends. S5, the driver keeps the gear engaged as prompted by the instruction display (13) and opens the door (8). At this time, the test host (14) detects that the door (8) is open through the door motion sensor (9), and the test program enters the next test process. S6, wait for the preset data acquisition time. If the test host (14) detects an alarm light on the instrument panel through the industrial camera (12) or detects an alarm sound through the acquired sound signal, the test result of the power supply connection and disconnection program of the drive system is deemed qualified; otherwise, it is deemed unqualified.

9. The functional safety protection test method according to claim 7, characterized in that: When conducting power reduction warning, REESS low battery warning, and REESS thermal event alarm tests, the following steps are included: S1, the vehicle is powered on, and the driver selects the corresponding test item on the instruction display (13) and drives the vehicle normally; S2, after the test starts for a preset time, the test host (14) injects the corresponding low power message, low battery message or high temperature message into the vehicle through the vehicle OBD interface; S3, wait for the preset data acquisition time. If the test host (14) detects an alarm light on the dashboard through the industrial camera (12) or detects an alarm sound through the collected sound signal, the corresponding test is deemed qualified; otherwise, it is deemed unqualified.

10. The functional safety protection test method according to claim 7, characterized in that: The following steps are included when conducting a brake override test: S1, the vehicle is powered on, the driver selects the test item on the instruction display screen (13), presses the brake pedal (4) and engages gear, the test host (14) detects the brake pedal (4) being pressed through the brake pedal action sensor (5) and starts the test; S2, according to the prompt of the instruction display screen (13), press the accelerator pedal (2) and brake pedal (4) at the same time; S3, wait for the preset data acquisition time, if the test host (14) does not detect the wheel action sensor (7) action, the test result is deemed qualified, otherwise it is deemed unqualified.

11. The functional safety protection test method according to claim 7, characterized in that: The following steps are included when conducting a reverse driving test: S1, the vehicle is powered on, the driver selects the test item on the instruction display screen (13) and inputs the wheel rolling radius and the vehicle speed threshold for engaging reverse gear while driving; S2, the driver presses the brake pedal (4) and engages the gear to drive normally; S3, the driver presses the accelerator pedal (2), the test host (14) detects the vehicle driving through the wheel motion sensor (7) and starts the test, and calculates the driving speed based on the Z-axis angular velocity and rolling radius; S4, when the driving speed exceeds the speed threshold, the instruction display screen (13) prompts the driver to engage reverse gear; after the driver engages reverse gear, the test host (14) detects the gear shift lever (10) movement through the gear position motion sensor (11) and starts recording test data; S5, within the preset recording time, the test result is determined to be qualified based on the positive and negative values ​​of the Z-axis angular velocity of the wheel motion sensor (7).

12. The functional safety protection test method according to claim 7, characterized in that: The following steps are included in the vehicle-to-external conductive connection locking test: S1, the vehicle is plugged into the charging gun and powered on. The driver selects the test item on the instruction display screen (13). S2, the driver presses the brake pedal (4) and shifts gears. The test host (14) detects the brake pedal (4) being pressed through the brake pedal action sensor (5) and starts the test. S3, the driver presses the accelerator pedal (2) according to the prompt on the instruction display screen (13). The test host (14) detects the accelerator pedal (2) being pressed through the accelerator pedal action sensor (3) and starts recording test data. S4, after the preset time is reached, the test host (14) checks whether the wheel action sensor (7) has been activated. If it is activated, the test result is deemed unqualified.

13. The functional safety protection test method according to any one of claims 6-12, characterized in that: The functional safety protection test method can be tested both indoors and outdoors; when testing indoors, the agricultural machine under test (1) is parked on the dynamometer.

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