A gas engine static OBD detection system and method

Abstract

The application discloses a kind of gas engine static OBD detection system and method, it is related to gas engine detection technical field;Including: initialization module: for carrying out initialization verification work of operating environment, after completing verification, corresponding detection parameter of machine type is loaded based on the electronic control unit information read;Its technical points are: the application adopts four-layer intelligent architecture of initialization, intelligent detection, identification early warning and detection filing, through the full amount data such as acquisition sensor / actuator on-off state, voltage, fault code, interference information is stripped using mean filtering, deviation calculation and other algorithms and extracts core features, then carry out fault identification and machine type adaptation, generate detection report and issue early warning through result fusion;Precise fault identification result and efficient detection process are obtained, the intelligentization and standardization of detection process are realized, can improve the rate of implicit fault identification, shorten machine type adaptation time, improve single equipment detection efficiency, with good use prospect.

Description

Technical Field

[0001] This invention relates to the field of gas engine testing technology, specifically to a static OBD testing system and method for gas engines. Background Technology

[0002] OBD stands for On-Board Diagnostics for Emission Control. The OBD device monitors multiple systems and components, including the engine, catalytic converter, particulate filter, oxygen sensor, emission control system, fuel system, exhaust gas recirculation, etc., and connects to the electronic control unit by analyzing information from these components. The electronic control unit has the function of detecting and analyzing emission-related faults. When an emission fault occurs, the electronic control unit records fault information and related codes, and issues a warning through the malfunction indicator lamp to inform the driver. At the same time, it ensures access to and processing of fault information through a standard data interface.

[0003] The principle of OBD static testing for gas engines: OBD static testing is a check performed by the electronic control unit on the working status of key electrical components of the entire electronic control system without starting the engine. It is a check to determine whether the system is conducting or disconnected when the system is powered on but all components are in a static state.

[0004] Existing technologies have significant drawbacks: low level of intelligence in detection, relying heavily on manual selection, operation, and fault diagnosis, which is prone to operational errors and leads to insufficient detection accuracy; incomplete fault identification, only able to detect explicit faults such as open circuits and short circuits, unable to identify implicit faults such as signal drift and loose connections, easily resulting in missed faults; low detection efficiency, with time-consuming manual sorting of model parameters, loading of detection parameters, and analysis of fault data, making it difficult to adapt to the needs of mass production; and lack of a closed-loop optimization mechanism, making it impossible to effectively reuse detection data, hindering the continuous improvement of detection accuracy, and failing to meet increasingly stringent quality control and emission compliance requirements.

[0005] In summary, existing gas engine testing systems do not meet market requirements. Therefore, we propose a static OBD testing system and method for gas engines. Summary of the Invention

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A static OBD detection system for gas engines includes an initialization module, an intelligent detection module, an identification and early warning module, and a detection archiving module.

[0008] Initialization module: Used to perform initialization verification of the operating environment. After verification, it loads the detection parameters for the corresponding model based on the read electronic control unit information.

[0009] The intelligent detection module sequentially completes the hardware connection verification, electronic control unit power-on initialization detection, sensor intelligent detection, actuator intelligent detection, and OBD core diagnostic intelligent detection steps to build a detection dataset.

[0010] Identification and early warning module: Integrates various detection data in the detection dataset, classifies faults into two categories: obvious faults and latent faults, sorts them according to the severity of the faults, locates the root cause of the fault, outputs a complete fault report containing maintenance suggestions, and executes quality early warning based on the complete fault report;

[0011] The detection and archiving module analyzes complete fault reports, marks the causes of faults and maintenance suggestions based on the output results, generates standardized detection reports, and completes storage and archiving.

[0012] Preferably, the initialization verification of the operating environment includes: verifying the environment in which the emission OBD static detection platform is located, determining whether there is any risk in the environment, and completing the hardware equipment check if there is no risk; performing software parameter verification; and completing the preparation of the test device.

[0013] The verification of the environment in which the emission OBD static detection platform is located includes: checking whether the ambient temperature, dust concentration and electromagnetic interference intensity are within the preset range, verifying whether the emergency stop switch can be triggered normally at any time, and checking the grounding of the workstation. If all are within the preset range, the emergency stop switch can be triggered normally at any time, and the workstation is grounded, then it is judged as no risk; otherwise, it is judged as risk, the detection is suspended, and the risk is eliminated.

[0014] The hardware testing includes checking whether the emission OBD static detection platform has aging problems and whether there are abnormal delays in interface communication; the software parameter verification work includes completing model initialization; the test component preparation work includes calibrating the model of the electronic control unit of the gas engine under test and confirming that the pins of the electronic control unit are free from oxidation, deformation and bending.

[0015] Preferably, the hardware connection verification includes using a dedicated foolproof adapter harness to connect the electronic control unit interface of the testing equipment to the electronic control unit under test, monitoring the harness connection status in real time, collecting impedance and voltage data of the connection points and analyzing the connection status; if the connection status is determined to be a loose connection, incorrect connection or poor contact, an audio-visual alarm is triggered; if the connection status is normal, the electronic control unit power-on initialization test is performed.

[0016] Preferably, the power-on initialization detection of the electronic control unit includes: providing a stable 24V standard voltage to the electronic control unit and performing a standby self-test of the electronic control unit without starting the engine; real-time acquisition of data related to the power-on sequence, power supply voltage stability, and self-test status of the electronic control unit; after acquisition, the voltage data is processed by a mean filtering algorithm to remove interference signals such as instantaneous voltage surges; the data after interference removal is compared with the standard initialization feature data. If the power-on sequence of the electronic control unit is normal and there is no overvoltage or undervoltage condition in the power supply voltage, the self-test is determined to be normal, and the sensor intelligent detection stage is entered; otherwise, the self-test is determined to be abnormal, and the power supply to the electronic control unit is cut off.

[0017] Preferably, intelligent sensor detection includes first sorting out the sensor list of the current model under test, locating each type of sensor in sequence, and controlling relays and manual switches to switch the on and off of each type of sensor in sequence, simulating connector plugging and unplugging operations; at the same time, it collects sensor data in real time, including sensor on / off status, on / off response time, and corresponding indicator light status, compares the collected sensor data with standard on / off characteristics, and identifies sensor circuit open circuit, short circuit, and loose connection type obvious faults;

[0018] After continuity testing is completed, the signal characteristic testing phase begins: The sensors are kept in normal connection mode, and the voltage, current, and impedance signal data output by the sensors are collected in real time; the deviation between the actual signal and the standard signal is calculated using the signal deviation value formula, and the signal drift trend is analyzed using the signal drift rate formula to identify latent faults such as signal drift and signal attenuation; for each type of sensor tested, the corresponding test data is recorded, marked as qualified or unqualified, and a real-time pop-up notification is provided for unqualified items; after all sensor tests are completed, all test data is summarized to generate a sensor test sub-report, clearly indicating the qualified / unqualified sensor name, fault type, and fault location.

[0019] Preferably, the intelligent actuator detection includes: first, compiling an actuator list and determining the corresponding detection parameters for each type of actuator; then, sequentially performing continuity and power supply detection: by controlling relays and manual switches, performing continuity switching operations on various types of actuators one by one, simulating the plugging and unplugging process of connectors; simultaneously collecting the continuity status and power supply voltage data of actuator pins, comparing the collected data with standard continuity and power supply characteristics, and identifying actuator circuit breaks, loose connections, and power supply abnormalities; during the detection process, the equipment indicator lights synchronously display the continuity status of each actuator, and the indicator light data is synchronized in real time.

[0020] Conduct control response testing of electronic control units (ECUs): Send control commands to the ECU via a host computer to simulate the normal control logic of the ECU on the actuators; collect feedback signals from the ECU and response signals from the actuators, compare the collected signals with the standard response characteristics in the preset model to determine whether the communication between the actuator and the ECU is normal and whether the actuator can respond normally to the control commands of the ECU; if an abnormal response is detected, associate the corresponding fault code, locate the root cause of the fault, and record the fault details; after all actuator tests are completed, summarize all test data, generate an actuator test sub-report, mark qualified / unqualified actuators, fault type, and preliminary maintenance suggestions, and merge this sub-report with the sensor test sub-report for archiving.

[0021] Preferably, the OBD core diagnostic intelligent detection includes: performing fault simulation detection, the simulation detection content including sensor open circuit, sensor short circuit, sensor signal drift, as well as actuator open circuit, actuator short circuit, actuator signal drift; after the fault simulation is triggered, the fault codes generated by the electronic control unit are collected in real time, and the collected fault codes are compared with the preset fault code rule base to verify the accuracy, completeness and standardization of the fault codes, and the trigger time, fault code and signal characteristics of each type of fault are recorded; the working status of the fault indicator light is monitored in real time and compared with standard logic to determine whether the fault indicator light function is normal; at the same time, the fault freeze frame data of the electronic control unit is read, the fault freeze frame data of the electronic control unit includes the fault trigger time, engine condition and power supply voltage;

[0022] Perform OBD readiness status and communication detection: Read the OBD readiness status bit of the electronic control unit to confirm that all non-critical monitoring items are ready and that there are no incomplete monitoring items blocking the detection process; at the same time, collect bus communication data to confirm that there are no frame drops or interruptions on the bus.

[0023] Conduct fault clearing function test: Control the host computer to send fault clearing command, collect the status data of the electronic control unit after fault clearing, confirm that the fault code can be completely cleared and there is no historical residue, the electronic control unit resets normally, the OBD diagnostic function returns to normal, and record all test data.

[0024] Preferably, faults are divided into two categories: explicit faults and implicit faults. Explicit faults are those that are directly observable and can be detected, specifically including open circuits, short circuits, and abnormal power supply in sensor / actuator circuits. Implicit faults are faults other than explicit faults, specifically including signal drift, signal attenuation, on / off response delays, and loose connections. Faults are ranked according to their severity, ranging from minor faults that do not affect OBD compliance and can be repaired later; general faults that affect the pass rate of testing and require immediate repair; and severe faults that affect emission compliance and prohibit the removal of the line from service.

[0025] Preferably, the quality early warning based on the complete fault report includes: calculating the detection comprehensive qualification Q of a single engine through the comprehensive qualification formula. When Q≥0.95, the detection result is determined to be qualified; otherwise, the detection result is determined to be unqualified. Based on the fault severity and the detection result, trigger the quality early warning. The quality early warning is as follows: when a single engine is detected as unqualified or has a serious fault, trigger an audible and visual alarm, and a pop-up window prompt on the upper computer. At the same time, send the signal to the production line interception device to prevent unqualified engines from going offline, and prompt the operator to carry out maintenance operations according to the complete fault report. After the maintenance is completed, it is necessary to conduct a re-detection. When the same fault appears on 3 or more engines of the same model and the same component continuously, it is determined that there is a batch quality hidden danger, trigger a batch early warning, and prompt the production line management personnel to check the quality of the tooling equipment, wire harness batch, and electronic control unit batch, and promptly investigate the problems existing in the production link. When the OBD diagnostic detection is unqualified and affects compliance, trigger a compliance early warning, and prompt the operator to focus on investigating OBD-related faults. All early warning signals are synchronously uploaded to the factory manufacturing execution system.

[0026] Preferably, a static OBD detection method for a gas engine includes:

[0027] Carry out the initialization verification work of the operating environment. After the verification is completed, load the detection parameters of the corresponding model based on the read electronic control unit information;

[0028] Successively complete the hardware connection verification, the power-on initialization detection of the electronic control unit, the intelligent detection of sensors, the intelligent detection of actuators, and the intelligent detection link of the OBD core diagnosis, and construct a detection data set;

[0029] Integrate the detection data in the detection data set, divide the faults into two categories: obvious faults and hidden faults, sort them according to the fault severity, then locate the root cause of the faults, output a complete fault report including maintenance suggestions, and perform quality early warning based on the complete fault report;

[0030] Analyze the complete fault report, mark the fault causes and maintenance suggestions according to the output results, generate a standardized detection report and complete the storage and archiving.

[0031] The present invention provides a static OBD detection system and method for a gas engine, which has the following beneficial effects:

[0032] This invention employs a four-layer intelligent architecture encompassing initialization, intelligent detection, identification and early warning, and detection archiving. It collects comprehensive data, including sensor / actuator on / off status, voltage, and fault codes. Algorithms such as mean filtering and deviation calculation are used to remove interference and extract core features. Fault identification and model adaptation are then performed. Finally, a detection report is generated and an early warning is issued through result fusion. This invention solves the technical problems of large human error, inability to identify latent faults, and low detection efficiency in existing technologies. It achieves accurate fault identification results and an efficient detection process, realizing intelligent and standardized detection. This improves the latent fault identification rate, reduces model adaptation time to less than 30 seconds, increases the detection efficiency of a single device, effectively reduces fault omissions and labor costs, and ensures the accuracy and efficiency of detection results.

[0033] This invention integrates data from the entire process, including preliminary preparation, calibration, graded testing, fault early warning, and result archiving. It uses a comprehensive pass / fail algorithm at the output decision layer to complete quality control judgment, solving the technical problems of unreusable testing data, difficulty in continuously improving testing accuracy, and the disconnect between quality control and testing in existing technologies. It provides full-process quality control support, achieving a synergistic improvement in testing accuracy, quality control level, and model performance. It can ensure the pass / fail status of individual gas engine OBD testing, provide early warning of batch quality risks, and continuously adapt to new models and fault types through model self-optimization. This provides production plants with a full-process, intelligent static OBD testing solution with promising application prospects. Attached Figure Description

[0034] Figure 1 This is a framework diagram of a static OBD detection system for a gas engine according to the present invention;

[0035] Figure 2 This is a framework diagram of an emission OBD static detection platform in a gas engine static OBD detection system according to the present invention;

[0036] Figure 3 This is a flowchart of a static OBD testing method for a gas engine according to the present invention. Detailed Implementation

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] Example 1:

[0039] Please see Figure 1This embodiment provides a static OBD detection system for gas engines, including an initialization module, an intelligent detection module, an identification and early warning module, and a detection archiving module.

[0040] Initialization module: Used to perform initialization verification of the operating environment. After verification, it loads the detection parameters for the corresponding model based on the read electronic control unit information.

[0041] The initialization verification of the operating environment includes: verifying the environment in which the emission OBD static detection platform is located, determining whether there are any risks in the environment, and completing the hardware equipment check if there are no risks; performing software parameter verification; and completing the preparation of the test components.

[0042] The verification of the environment in which the emission OBD static detection platform is located includes: checking whether the ambient temperature, dust concentration and electromagnetic interference intensity are within the preset range, verifying whether the emergency stop switch can be triggered normally at any time, and checking the grounding of the workstation to eliminate the hidden dangers of static electricity and leakage, and to ensure the safe operation of the equipment and electronic control unit. If all are within the preset range, the emergency stop switch can be triggered normally at any time, and the workstation is grounded, then it is judged to be risk-free; otherwise, it is judged to be risky, the detection is suspended, and the risk is eliminated.

[0043] The hardware testing includes checking whether the emission OBD static detection platform has aging problems and whether there are abnormal delays in interface communication; the software parameter verification work includes completing model initialization; the test component preparation work includes calibrating the model of the electronic control unit of the gas engine under test and confirming that the pins of the electronic control unit are free from oxidation, deformation and bending.

[0044] The intelligent detection module sequentially completes the hardware connection verification, electronic control unit power-on initialization detection, sensor intelligent detection, actuator intelligent detection, and OBD core diagnostic intelligent detection steps to build a detection dataset.

[0045] Before intelligent detection, the data acquisition channels are tested, specifically covering the sensor / actuator signal acquisition channel, the electronic control unit data acquisition channel, the CAN / LIN bus communication channel, and the OBD diagnostic interface acquisition channel.

[0046] When collecting information from electronic control units (ECUs), a communication connection must be established with the ECU under test via a CAN bus to read the core information stored inside the ECU, including key data such as ECU model, production batch, compatible engine model, pin definitions, and sensor / actuator configuration list. After the information is read, the system automatically performs a preliminary comparison between the read ECU information and a pre-set multi-model parameter library to confirm that the ECU information is complete and identifiable.

[0047] Hardware connection verification includes using a dedicated foolproof adapter harness to connect the electronic control unit interface of the testing equipment to the electronic control unit under test, monitoring the harness connection status in real time, collecting impedance and voltage data of the connection points, and analyzing the connection status. If the connection status is determined to be loose, incorrect, or poor, the abnormal connection status is mainly determined based on two indicators: impedance exceeding the standard range and abnormal voltage fluctuation, and an audible and visual alarm is triggered. If the connection status is normal, the electronic control unit power-on initialization test is performed.

[0048] The power-on initialization test of the Electronic Control Unit (ECU) includes: providing a stable 24V standard voltage to the ECU and performing a standby self-test without starting the engine; real-time acquisition of data related to the ECU's power-on sequence, power supply voltage stability, and ECU self-test status; after acquisition, the voltage data is processed to remove interference using a mean filtering algorithm, which calculates the average voltage value after mean filtering; interference signals such as instantaneous voltage spikes are removed; the data after interference removal is compared with the standard initialization characteristic data. If the ECU's power-on sequence is normal and there is no overvoltage or undervoltage condition, the self-test is determined to be normal, and the sensor intelligent detection stage is entered; otherwise, the self-test is determined to be abnormal, and the power supply to the ECU is cut off.

[0049] Intelligent sensor detection includes: First, compiling a list of sensors for the current model under test, including types such as speed sensors, camshaft sensors, water temperature sensors, and pressure sensors; then, sequentially locating each type of sensor and using relays and manual switches to switch the on / off states of each sensor in turn, simulating connector plugging and unplugging operations; simultaneously, real-time acquisition of sensor data, including sensor on / off status, on / off response time, and corresponding indicator light status; comparing the acquired sensor data with standard on / off characteristics, including on / off response time thresholds and indicator light status logic, to identify sensor circuit open circuits, short circuits, and loose connections.

[0050] After the continuity test is completed, the signal characteristic detection stage begins: keeping the sensor in normal connection state, the voltage, current and impedance signal data output by the sensor are collected in real time; the deviation between the actual signal and the standard signal is calculated using the signal deviation value formula, that is, the difference between the actual signal and the standard signal; the signal drift trend is analyzed using the signal drift rate formula.

[0051] Identify latent faults such as signal drift and signal attenuation; record the corresponding test data after each type of sensor is tested, mark the qualified or unqualified status, and provide real-time pop-up prompts for unqualified items; after all sensor tests are completed, summarize all test data, generate a sensor test sub-report, clearly mark the qualified / unqualified sensor names, fault types, and fault locations, and provide basic support for subsequent fault identification work.

[0052] Signal drift rate = |Signal deviation value of the second acquisition - Signal deviation value of the first acquisition| / (Time of the second acquisition - Time of the first acquisition);

[0053] Intelligent actuator detection includes: first, compiling an actuator list, which in this case includes exhaust gas recirculation valves, electronic throttle valves, and urea pumps; determining the corresponding detection parameters for each type of actuator, such as standard power supply voltage and on / off thresholds; then, sequentially performing on / off detection and power supply detection: by controlling relays and manual switches, the on / off switching operations of various actuators are completed one by one, simulating the plugging and unplugging process of connectors; simultaneously collecting the on / off status of actuator pins and power supply voltage data, comparing the collected data with standard on / off characteristics and power supply characteristics to identify actuator circuit open circuits, loose connections, and power supply abnormalities; during the detection process, the equipment indicator lights synchronously display the on / off status of each actuator, with real-time synchronization of indicator light data;

[0054] Conduct electronic control unit (ECU) control response testing: Send control commands to the ECU via a host computer to simulate the ECU's normal control logic for the actuators; collect ECU feedback signals and actuator response signals, compare the collected signals with standard response characteristics in a preset model to determine whether the communication between the actuator and the ECU is normal and whether the actuator can respond normally to the ECU's control commands; if an abnormal response is detected, associate the corresponding fault code, locate the root cause of the fault, such as actuator damage, wiring fault, or ECU control logic abnormality; and record the fault details; after all actuator tests are completed, summarize all test data, generate an actuator test sub-report, mark qualified / unqualified actuators, fault type, and preliminary repair suggestions, and merge this sub-report with the sensor test sub-report for archiving.

[0055] OBD core diagnostic intelligent detection includes: performing fault simulation detection, including sensor open circuit, sensor short circuit, sensor signal drift, as well as actuator open circuit, actuator short circuit, and actuator signal drift; after the fault simulation is triggered, fault codes generated by the electronic control unit are collected in real time, and the collected fault codes are compared with a preset fault code rule base to verify the accuracy, completeness, and standardization of the fault codes. Accuracy is determined by whether the detected fault code is the same as the simulated fault type, completeness by whether no codes are missed, and standardization by whether no codes are missed; recording the trigger time, fault code, and signal characteristics of each type of fault; real-time monitoring of the working status of the fault indicator light and comparing it with standard logic, which is: the fault indicator light illuminates when a fault is triggered and turns off when a fault is cleared; determining whether the fault indicator light function is normal; and simultaneously reading the electronic control unit fault freeze frame data, which includes the fault trigger time, engine operating condition, and power supply voltage.

[0056] Perform OBD readiness status and communication detection: Read the OBD readiness status bit of the electronic control unit to confirm that all non-critical monitoring items are ready and that there are no incomplete monitoring items blocking the detection process; at the same time, collect bus communication data to confirm that there are no frame drops or interruptions on the bus.

[0057] Conduct fault clearing function test: Control the host computer to send fault clearing command, collect the status data of the electronic control unit after fault clearing, confirm that the fault code can be completely cleared and there is no historical residue, the electronic control unit resets normally, the OBD diagnostic function returns to normal, and record all test data.

[0058] Identification and early warning module: Integrates various detection data in the detection dataset, classifies faults into two categories: obvious faults and latent faults, sorts them according to the severity of the faults, locates the root cause of the fault, outputs a complete fault report containing maintenance suggestions, and executes quality early warning based on the complete fault report;

[0059] Faults are categorized into two types: overt and covert. Overt faults are those that are readily observable and can be detected, including open circuits, short circuits, and abnormal power supply in sensor / actuator circuits. Covert faults are those other than overt faults, including signal drift, signal attenuation, delays in on / off response, and loose connections. Faults are also ranked according to their severity, ranging from minor faults that do not affect OBD compliance and can be repaired later; to general faults that affect testing compliance and require immediate repair; and to serious faults that affect emission compliance and prohibit removal from the production line.

[0060] Following this, root cause localization is conducted, specifically divided into three categories: For circuit-related faults, the exact location of the fault is identified, such as a loose connection in a sensor harness or an open circuit in an actuator pin, with continuity test data used to describe the fault symptoms; for component-related faults, the corresponding component is identified, such as signal drift in a sensor or abnormal response in an actuator, with signal deviation values ​​and drift rates used to describe the severity of the fault; for diagnostic faults, the specific type of fault is identified, such as garbled fault codes, malfunctioning fault indicator lights, or OBD communication anomalies, with OBD diagnostic data used to describe the impact of the fault. A complete fault report is generated, covering the name of the faulty component, fault type, fault location, root cause, and severity of the fault. It also provides targeted repair suggestions based on maintenance specifications and practical experience, such as re-inserting and securing a loose harness or replacing a sensor with a drifting signal. The complete fault report can be viewed in real time, providing clear repair guidance for production line operators and avoiding blind repair work.

[0061] Inspection and archiving module: Analyzes complete fault reports, marks the causes of faults and maintenance suggestions based on the output results, generates standardized inspection reports and completes storage and archiving, storing them in the database.

[0062] The quality warning based on the complete fault report includes: calculating the comprehensive pass rate Q of a single engine using the comprehensive pass rate formula, Q=a×Q1+b×Q2+c×Q3+d×Q4; where Q1, Q2, Q3, and Q4 are the scores for evaluating the test results based on the electronic control unit power-on initialization test, sensor intelligent test, actuator intelligent test, and OBD core diagnostic intelligent test, respectively; a, b, c, and d are the weight coefficients corresponding to the four scores, specifically 0.3, 0.3, 0.3, and 0.1; when Q≥0.95, the test result is judged as qualified; otherwise, the test result is judged as unqualified; based on the severity of the fault and the test result, a quality warning will be triggered. The quality warning is as follows: when a single engine fails the test or has a serious fault, an audible and visual alarm will be triggered, and a pop-up window will be displayed on the host computer. The signal is sent to the production line interception device to prevent unqualified engines from leaving the line, and operators are prompted to carry out repair work based on the complete fault report. After the repair is completed, re-testing is required. When three or more units of the same model of the same component have the same fault, such as when a batch of sensors all show signal drift, it is determined that there is a potential batch quality problem, triggering a batch warning. This prompts production line managers to check the quality of tooling equipment, wiring harness batches, and electronic control unit batches, and promptly investigate problems in the production process. When OBD diagnostic tests fail, such as abnormal fault codes, malfunctioning fault indicator lights, or abnormal OBD communication, and this affects compliance, a compliance warning is triggered, prompting operators to focus on investigating OBD-related faults. All warning signals are simultaneously uploaded to the factory's manufacturing execution system, facilitating real-time monitoring and overall scheduling by management personnel.

[0063] All test data will be automatically stored and synchronized to the factory's manufacturing execution system. The system can generate standardized test reports containing core information such as machine model and test results, and supports export in Excel and PDF formats to meet the requirements of production line quality control processes.

[0064] Example 2:

[0065] like Figure 2 As shown, a static OBD testing method for a gas engine includes:

[0066] The initialization verification of the operating environment is carried out. After the verification is completed, the detection parameters of the corresponding model are loaded based on the read electronic control unit information.

[0067] The hardware connection verification, electronic control unit power-on initialization detection, sensor intelligent detection, actuator intelligent detection, and OBD core diagnostic intelligent detection are completed sequentially to build a detection dataset.

[0068] The system integrates all the detection data in the detection dataset, classifies the faults into two categories: explicit faults and implicit faults, sorts them according to the severity of the faults, locates the root cause of the fault, outputs a complete fault report containing maintenance suggestions, and executes quality warnings based on the complete fault report.

[0069] Analyze the complete fault report, mark the cause of the fault and maintenance suggestions based on the output results, generate a standardized test report and complete storage and archiving.

[0070] like Figure 3 As shown, the emission OBD static testing platform adopts a split design, with the electrical cabinet and the support part being independent of each other. The electrical cabinet is the main body of the OBD static testing equipment, and all electrical components are integrated and installed inside the cabinet. The core operation is completed through the control buttons set on the front panel. The support part adopts a steel-wood cabinet or steel cabinet structure, with the same height as a conventional office desk, and is equipped with an office chair to meet the needs of operators to place laptops and various testing tools.

[0071] The emission OBD static testing platform supplies power to system components such as the electronic control unit (ECU) and indicator lights via a switching power supply. Through the cooperation of manual switches and relays, it realizes the on / off control of the connection between sensors, actuators and ECU, thereby simulating the plugging and unplugging operation of connectors. At the same time, during the switching process, the indicator lights can synchronously display the on / off status of sensor or actuator signals.

[0072] The emission OBD static detection platform adopts a partitioned panel design, which centrally arranges similar sensors and is compatible with multiple models. The panel is made of 3mm thick aluminum alloy sheet with an anodized and sandblasted surface. The panel has reserved installation space for sensors and actuators, and L-shaped fixing plates are used to fix the sensors and actuators. The panel has corresponding openings for mounting plate fixing, plug wiring, indicator lights, switches, and wiring harness interfaces. In addition, the panel uses silkscreen printing to print the actual names and warning text of the corresponding components.

[0073] The core of OBD static inspection equipment lies in circuit control. It uses switches and relays to control the on / off of sensor and actuator signals, thereby simulating the plugging and unplugging of sensor and actuator connectors to characterize whether the sensor and actuator are connected to the system. When multiple models of the same sensor exist, the system can connect only the sensor that matches the selected model according to the model selected in the host computer software, while keeping the other sensors disconnected. Based on this, the operator can perform on / off operations on the sensor either in the host computer software or manually.

[0074] After the model selection is completed, the sensor and actuator signals adopt a two-level control scheme combining switches and relays: the relay realizes the matching selection of the sensor (actuator) and the model and the control of the signal, while the manual switch realizes the manual on / off control of the selected signal (sensor or actuator); depending on the number of pins of the sensor and actuator, a single-channel or multi-channel control scheme can be adopted to realize the overall or individual on / off control of the sensor or actuator signal.

[0075] Indicator lights are used to indicate power status, sensor and actuator switching, and on / off status of sensor and actuator signals. The power indicator light is controlled by the power switch and is used to indicate the power supply status of the equipment. The on / off indicator light is controlled by the signal switch and is located next to the sensor and actuator. It is controlled synchronously with the on / off switch of the sensor or actuator signal and is used to indicate the on / off status of the current signal.

[0076] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented in software, the above embodiments can be implemented, in whole or in part, as a computer program product. Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution.

[0077] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment, depending on actual needs.

[0078] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application.

Claims

1. A static OBD detection system for a gas engine, characterized in that, include: Initialization module: Used to perform initialization verification of the operating environment. After verification, it loads the detection parameters for the corresponding model based on the read electronic control unit information. The intelligent detection module sequentially completes the hardware connection verification, electronic control unit power-on initialization detection, sensor intelligent detection, actuator intelligent detection, and OBD core diagnostic intelligent detection steps to build a detection dataset. Identification and early warning module: Integrates various detection data in the detection dataset, classifies faults into two categories: obvious faults and latent faults, sorts them according to the severity of the faults, locates the root cause of the fault, outputs a complete fault report containing maintenance suggestions, and executes quality early warning based on the complete fault report; The detection and archiving module analyzes complete fault reports, marks the causes of faults and maintenance suggestions based on the output results, generates standardized detection reports, and completes storage and archiving.

2. The static OBD detection system for a gas engine according to claim 1, characterized in that: The initialization verification of the operating environment includes: verifying the environment in which the emission OBD static detection platform is located, determining whether there are any risks in the environment, and completing the hardware equipment check if there are no risks; performing software parameter verification; and completing the preparation of the test components. The verification of the environment in which the emission OBD static detection platform is located includes: checking whether the ambient temperature, dust concentration and electromagnetic interference intensity are within the preset range, verifying whether the emergency stop switch can be triggered normally at any time, and checking the grounding of the workstation. If all are within the preset range, the emergency stop switch can be triggered normally at any time, and the workstation is grounded, then it is judged as no risk; otherwise, it is judged as risk, the detection is suspended, and the risk is eliminated. The hardware testing includes checking whether the emission OBD static detection platform has aging problems and whether there are abnormal delays in interface communication; the software parameter verification work includes completing model initialization; the test component preparation work includes calibrating the model of the electronic control unit of the gas engine under test and confirming that the pins of the electronic control unit are free from oxidation, deformation and bending.

3. The static OBD detection system for a gas engine according to claim 2, characterized in that: Hardware connection verification includes using a dedicated foolproof adapter harness to connect the electronic control unit interface of the testing equipment to the electronic control unit under test, monitoring the harness connection status in real time, collecting impedance and voltage data of the connection points and analyzing the connection status; if the connection status is determined to be loose, incorrect, or poor contact, an audible and visual alarm is triggered; if the connection status is normal, the electronic control unit power-on initialization test is performed.

4. The static OBD detection system for a gas engine according to claim 1, characterized in that: The power-on initialization test of the electronic control unit (ECU) includes: providing a stable 24V standard voltage to the ECU and performing a standby self-test without starting the engine; real-time acquisition of data related to the ECU's power-on sequence, power supply voltage stability, and self-test status; after acquisition, the voltage data is processed using a mean filtering algorithm to remove interference signals such as instantaneous voltage spikes; the data after interference removal is compared with the standard initialization characteristic data. If the ECU's power-on sequence is normal and there is no overvoltage or undervoltage condition, the self-test is determined to be normal, and the system enters the sensor intelligent detection stage; otherwise, the self-test is determined to be abnormal, and the power supply to the ECU is cut off.

5. A static OBD detection system for a gas engine according to claim 4, characterized in that: Intelligent sensor detection includes: first, sorting out the sensor list of the current model under test, locating each type of sensor in sequence, and controlling relays and manual switches to switch the on and off of each type of sensor in sequence, simulating connector plugging and unplugging operations; at the same time, collecting sensor data in real time, including sensor on / off status, on / off response time, and corresponding indicator light status, comparing the collected sensor data with standard on / off characteristics, and identifying sensor circuit open circuit, short circuit, and loose connection type obvious faults; After continuity testing is completed, the signal characteristic testing phase begins: The sensors are kept in normal connection mode, and the voltage, current, and impedance signal data output by the sensors are collected in real time; the deviation between the actual signal and the standard signal is calculated using the signal deviation value formula, and the signal drift trend is analyzed using the signal drift rate formula to identify latent faults such as signal drift and signal attenuation; for each type of sensor tested, the corresponding test data is recorded, marked as qualified or unqualified, and a real-time pop-up notification is provided for unqualified items; after all sensor tests are completed, all test data is summarized to generate a sensor test sub-report, clearly indicating the qualified / unqualified sensor name, fault type, and fault location.

6. The static OBD detection system for a gas engine according to claim 1, characterized in that: Intelligent actuator detection includes: first, compiling an actuator list and determining the corresponding detection parameters for each type of actuator; then, sequentially performing continuity and power supply detection: by controlling relays and manual switches, the continuity switching operation of various actuators is completed one by one, simulating the plugging and unplugging process of connectors; simultaneously collecting the continuity status and power supply voltage data of actuator pins, comparing the collected data with standard continuity and power supply characteristics, and identifying actuator circuit open circuits, loose connections, and power supply abnormalities; during the detection process, the equipment indicator lights synchronously display the continuity status of each actuator, and the indicator light data is synchronized in real time; Conduct control response testing of electronic control units (ECUs): Send control commands to the ECU via a host computer to simulate the normal control logic of the ECU on the actuators; collect feedback signals from the ECU and response signals from the actuators, compare the collected signals with the standard response characteristics in the preset model to determine whether the communication between the actuator and the ECU is normal and whether the actuator can respond normally to the control commands of the ECU; if an abnormal response is detected, associate the corresponding fault code, locate the root cause of the fault, and record the fault details; after all actuator tests are completed, summarize all test data, generate an actuator test sub-report, mark qualified / unqualified actuators, fault type, and preliminary maintenance suggestions, and merge this sub-report with the sensor test sub-report for archiving.

7. A static OBD detection system for a gas engine according to claim 6, characterized in that: The OBD core diagnostic intelligent detection includes: conducting fault simulation detection, and the simulation detection content includes sensor open circuit, sensor short circuit, sensor signal drift, as well as actuator open circuit, actuator short circuit, actuator signal drift; after the fault simulation is triggered, the fault codes generated by the electronic control unit are collected in real time, and the collected fault codes are compared with the preset fault code rule library to verify the accuracy, integrity and standardization of the fault codes, and record the trigger time, fault codes and signal characteristics of each type of fault; the working status of the fault indicator light is monitored in real time and compared with the standard logic to determine whether the function of the fault indicator light is normal; at the same time, the fault freeze frame data of the electronic control unit is read, and the fault freeze frame data of the electronic control unit includes the fault trigger time, engine working condition and power supply voltage; Execute the OBD ready state and communication detection: read the OBD ready state bit of the electronic control unit to confirm that all non-critical monitoring items are ready and there is no unfinished monitoring item blocking the detection process; at the same time, collect the bus communication data to confirm that there is no frame loss and no interruption abnormality in the bus; Conduct the fault clearing function detection: control the host computer to send a fault clearing instruction, collect the state data of the electronic control unit after the fault is cleared, and after confirming that the fault code can be completely cleared and there is no historical residue, the electronic control unit resets normally, the OBD diagnostic function resumes normal, and all detection data are recorded.

8. A static OBD detection system for a gas engine according to claim 7, characterized in that: The faults are divided into two categories: obvious faults and hidden faults. Among them, the obvious faults are faults that can be directly detected, specifically including open circuit, short circuit and abnormal power supply of the sensor / actuator line, and the hidden faults are faults other than the obvious faults, specifically including signal drift, signal attenuation, on-off response delay and virtual connection, etc.; Sorted according to the severity of the fault, the severity of the fault includes minor faults that do not affect OBD compliance and can be repaired later; general faults that affect the detection qualification and need to be repaired immediately; Serious faults that affect emission compliance and are prohibited from leaving the line.

9. A static OBD detection system for a gas engine according to claim 6, characterized in that: Based on the complete fault report, quality early warning is executed, including: calculating the comprehensive qualification Q of a single engine through the comprehensive qualification formula. When Q≥0.95, the detection result is judged to be qualified, otherwise, the detection result is judged to be unqualified; based on the severity of the fault and the detection result, quality early warning will be triggered. The quality early warning is: when the detection of a single engine is unqualified or there is a serious fault, an audible and visual alarm is triggered, a pop-up window of the host computer is prompted, and at the same time, the signal is sent to the production line interception device to prohibit the unqualified engine from leaving the line, and prompt the operator to carry out repair operations according to the complete fault report. After the repair is completed, the detection needs to be carried out again; when the same fault appears in 3 or more engines of the same model of the same component continuously, it is judged that there is a batch quality hidden danger, and a batch early warning is triggered to prompt the production line management personnel to check the quality of the tooling equipment, wire harness batch and electronic control unit batch, and timely investigate the problems existing in the production link; when the OBD diagnostic detection is unqualified and affects the compliance, a compliance early warning is triggered to prompt the operator to focus on investigating the OBD-related faults; all early warning signals are synchronously uploaded to the factory manufacturing execution system.

10. A static OBD testing method for a gas engine, characterized in that, Including: The initialization verification of the operating environment is carried out. After the verification is completed, the detection parameters of the corresponding model are loaded based on the read electronic control unit information. The hardware connection verification, electronic control unit power-on initialization detection, sensor intelligent detection, actuator intelligent detection, and OBD core diagnostic intelligent detection are completed sequentially to build a detection dataset. The system integrates all the detection data in the detection dataset, classifies the faults into two categories: explicit faults and implicit faults, sorts them according to the severity of the faults, locates the root cause of the fault, outputs a complete fault report containing maintenance suggestions, and executes quality warnings based on the complete fault report. Analyze the complete fault report, mark the cause of the fault and maintenance suggestions based on the output results, generate a standardized test report and complete storage and archiving.

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