Automobile engine electronic control unit performance diagnosis system and method

Abstract

The application discloses a performance diagnosis system and method for an electronic control unit of an automobile engine, and particularly relates to the technical field of engines, the system comprising a sensor diagnosis module, an actuator diagnosis module, an ECU self-diagnosis module, a dynamic enablement control module, a fault determination module and a three-high test calibration module; the diagnosis method detects engine states and sensor data, activates a diagnosis process based on preset enablement conditions, determines faults using a counter accumulation mechanism and outputs results. Through hierarchical diagnosis architecture and dynamic parameter calibration, the application realizes efficient diagnosis of sensors, actuators and ECU internals, can accurately identify faults such as short circuits and sticking, is suitable for extreme environments such as high altitudes and high temperatures, reduces false positive rates and power consumption, and provides protection for the reliability of a vehicle power system.

Description

Technical Field

[0001] This invention relates to the field of engine technology, and more specifically, to a system and method for diagnosing the performance of an electronic control unit for an automotive engine. Background Technology

[0002] The Electronic Control Unit (ECU) of an automotive engine is the core control component. By collecting signals from sensors such as intake air pressure, temperature, and position, it controls actuators such as fuel injectors, fans, and relays to precisely regulate engine functions such as fuel injection, ignition timing, and emissions. Its performance directly affects the engine's power, economy, and emissions levels. With the increasing complexity of automotive electronic control systems, ECUs may experience problems such as abnormal sensor signals, actuator drive circuit failures, and internal chip malfunctions during long-term operation. Therefore, an efficient ECU performance diagnostic system is crucial to ensuring reliable engine operation.

[0003] However, existing engine diagnostic systems have the following drawbacks: Traditional diagnostic systems are prone to problems such as misjudgment of the reasonable threshold of pressure sensors and deviation in fuel tank pressure diagnosis in extreme environments such as high altitude, high temperature, and high cold due to sensor characteristic deviation and changes in environmental parameters, leading to false alarms or missed alarms. Most diagnostic systems only detect short-circuit faults by using simple voltage thresholds, lacking a comprehensive diagnosis of the rationality of sensor data, stuck state, and internal functions of the ECU. They are unable to identify hidden faults under complex operating conditions, such as abnormal intake pressure during deceleration or insufficient changes in sensor data.

[0004] Existing systems often employ a continuous diagnostic mode, running the entire diagnostic process regardless of engine operating conditions and battery status. This results in high ECU power consumption and, under unstable operating conditions such as large throttle opening or low coolant temperature, is prone to misdiagnosis due to interference.

[0005] The diagnostics of the actuator drive circuit do not incorporate differentiated testing based on the operating status, making it impossible to accurately distinguish between power supply short circuits and ground short circuits. Furthermore, the lack of a counting and accumulation mechanism to filter transient interference results in insufficient diagnostic reliability.

[0006] Therefore, a performance diagnostic system and method for automotive engine electronic control units are proposed. Summary of the Invention

[0007] In order to overcome the above-mentioned defects of the prior art, the present invention provides a performance diagnostic system and method for an automotive engine electronic control unit to solve the problems mentioned in the background art.

[0008] To achieve the above objectives, the present invention provides the following technical solution: a performance diagnostic system for an automotive engine electronic control unit, comprising: Sensor diagnostic module: used to diagnose short circuits, malfunctions, interference, and jamming faults in intake pressure sensors, boost pressure sensors, atmospheric pressure sensors, temperature sensors, and position sensors; Actuator diagnostic module: used to diagnose short-circuit faults in the output drive circuits of fault lights, fans, canister solenoid valves, fuel injectors, and relays; ECU self-diagnostic module: used to detect faults in the ECU's software execution sequence, sensor power supply, clock, memory, watchdog timer, registers, AD conversion, and ignition function; Dynamic enable control module: dynamically enables or disables the diagnostic process based on battery voltage, engine status, sensor data thresholds, and environmental conditions; Fault determination module: Based on the counter accumulation mechanism, when the fault condition continuously meets the preset counting threshold, the fault flag is triggered, and the diagnostic result is output when the diagnostic counter reaches the completion threshold.

[0009] Preferably, the sensor diagnostic module includes: Short circuit diagnostic unit: detects whether the sensor voltage exceeds a preset threshold and determines the fault based on the accumulated result of the fault counter; Reasonableness diagnostic unit: Under idling or driving conditions, whether the difference between the data from multiple sensors exceeds the calibrated tolerance range; Stuck diagnostic unit: During engine operation, it detects whether the change in sensor data is below the dynamic threshold.

[0010] Preferably, the actuator diagnostic module includes: Dual-state diagnostic logic: Detects short-circuit faults to the power supply when the actuator is on, and detects short-circuit faults to ground when the actuator is off; Counting accumulation mechanism: When the fault continues, the counter accumulates with an increment step size; when the fault disappears, it decreases with a decrement step size.

[0011] Preferably, the ECU self-diagnostic module includes: Watchdog diagnostics: Detects whether the ECU software execution sequence times out; Memory diagnostics: Verify the integrity of non-volatile memory data; AD conversion diagnosis: Check whether the accuracy of analog signal conversion is out of tolerance.

[0012] Preferably, it further includes: The "Three Highs" test calibration module is used for dynamic calibration of diagnostic parameters in high-altitude, high-temperature, and high-cold environments, including: Reasonable threshold for pressure sensor correction in high-altitude environments; Calibrate the oil tank pressure cooling time in high-temperature environments.

[0013] A method for diagnosing the performance of an automotive engine electronic control unit includes the following steps: Step S1: Detect engine operating status, battery voltage, and sensor data; Step S2: Dynamically activate the diagnostic process based on preset enabling conditions, including: The battery voltage is in the range of 11V to 16V; The engine is running or ignited; No pending faults were found in the associated sensors; Environmental parameters meet the calibration thresholds; Step S3: When the sensor or actuator data exceeds the preset short-circuit threshold, the fault counter is triggered to accumulate; Step S4: If the fault counter reaches the first counting threshold, a fault is determined to have occurred; Step S5: When the diagnostic counter reaches the second counting threshold, the diagnosis is completed and a fault code is output.

[0014] Preferably, step S3 further includes: Under deceleration conditions, if the intake pressure exceeds the calibrated maximum value, the rationality fault counter will be triggered. In high-altitude environments, atmospheric pressure correction calibration is dynamically adjusted to avoid false alarms.

[0015] Preferably, the dynamic enabling condition further includes: Throttle opening is less than the calibrated limit; The engine coolant temperature is higher than the minimum threshold. The vehicle's power-off time exceeds the cooling threshold.

[0016] Preferably, the counting mechanism in step S3 includes: When the fault condition is met, the counter increments by an increment step of (1-3); When the fault condition is not met, the counter decreases by a decrement step size of (3-5). The fault flag is activated when the counter reaches the threshold.

[0017] The technical effects and advantages of this invention are as follows: 1. By using the short circuit, rationality, and jamming diagnostic unit of the sensor diagnostic module, combined with the counter accumulation mechanism, short circuits, data anomalies, and jamming faults of intake pressure sensors, boost pressure sensors, etc., can be accurately identified, reducing the false alarm rate.

[0018] 2. The high-altitude, high-temperature, and high-cold test calibration module can dynamically calibrate diagnostic parameters in high-altitude, high-temperature, and high-cold environments, such as correcting the reasonable threshold of the pressure sensor in high-altitude environments and adjusting the oil tank pressure cooling time in high-temperature environments, to ensure that the system maintains diagnostic accuracy in environments ranging from -40℃ to 125℃ and above 5000 meters above sea level.

[0019] 3. The ECU self-diagnostic module monitors the software execution sequence, memory, AD conversion and other internal functions in real time to avoid system failure due to ECU malfunction.

[0020] 4. The dynamic enable control module dynamically activates the diagnostic process based on conditions such as battery voltage and engine status, reducing unnecessary diagnostics and lowering ECU power consumption.

[0021] 5. Through the dual-state diagnostic logic and counting accumulation mechanism of the actuator diagnostic module, short-circuit faults in actuator drive circuits such as fault lights and fans can be accurately detected, avoiding false alarms caused by momentary interference. Attached Figure Description

[0022] Figure 1 This is a flowchart of the method of the present invention. Detailed Implementation

[0023] 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.

[0024] The automotive engine electronic control unit performance diagnostic system provided by this invention includes: Sensor diagnostic module: used to diagnose short circuits, malfunctions, interference, and jamming faults in intake pressure sensors, boost pressure sensors, atmospheric pressure sensors, temperature sensors, and position sensors; The sensor diagnostic module includes: Short circuit diagnostic unit: detects whether the sensor voltage exceeds a preset threshold and determines the fault based on the accumulated result of the fault counter; Reasonableness diagnostic unit: Under idling or driving conditions, whether the difference between the data from multiple sensors exceeds the calibrated tolerance range; Stuck diagnostic unit: During engine operation, it detects whether the change in sensor data is below the dynamic threshold.

[0025] In practical implementation, the short-circuit diagnostic unit, taking the intake pressure sensor as an example, triggers the power supply short-circuit fault flag when the sensor voltage is detected to be greater than 4.95V. The counter starts to accumulate in increments of 1, and when the count reaches 320, the fault is confirmed. When the voltage is less than 0.05V, the ground short-circuit diagnostic is triggered, and the fault is confirmed when the count reaches 320.

[0026] Reasonableness diagnostic unit: Under idling or driving conditions, compares the differences in data from multiple sensors. For example, if the intake pressure is greater than the calibrated maximum value under deceleration conditions, the reasonableness fault counter is triggered; in high-altitude environments, the atmospheric pressure correction calibration is dynamically adjusted to avoid false alarms.

[0027] Stuck diagnostic unit: During engine operation, it detects whether the change in sensor data is below a dynamic threshold. For example, in the intake air temperature sensor stuck diagnostic, if the data change is less than the threshold, the stuck fault is confirmed by cyclic counting under driving and idling conditions.

[0028] By employing voltage threshold detection, multi-sensor data comparison, and dynamic change analysis, combined with a counter accumulation mechanism—accumulating as the fault persists and decrementing when it disappears—a tiered diagnosis of sensor faults is achieved. For example, short-circuit diagnosis is based on voltage over-limit triggering, rationality diagnosis is based on data logic consistency judgment, and jamming diagnosis is based on dynamic response capability detection. This enables accurate identification of sensor short circuits, data anomalies, and jamming faults, reducing false alarm rates, adapting to complex environments such as high altitudes and high temperatures, and improving diagnostic reliability through dynamic calibration correction.

[0029] Actuator diagnostic module: used to diagnose short-circuit faults in the output drive circuits of fault lights, fans, canister solenoid valves, fuel injectors, and relays; The actuator diagnostic module includes: Dual-state diagnostic logic: Detects short-circuit faults to the power supply when the actuator is on, and detects short-circuit faults to ground when the actuator is off; Counting accumulation mechanism: When the fault continues, the counter accumulates with an increment step size; when the fault disappears, it decreases with a decrement step size.

[0030] In practice, when the actuator is turned on, a power short circuit is detected (e.g., when fan 1 is turned on, the voltage is greater than the threshold, triggering a fault). When the actuator is turned off, a short circuit to ground is detected (e.g., when fan 1 is turned off, the voltage is less than the threshold, triggering a fault).

[0031] Counting accumulation mechanism: Taking the charcoal canister solenoid valve as an example, when the fault continues, the counter accumulates by an increment step of 1, and when the fault disappears, it decreases by a decrement step of 3. The fault is confirmed when the count reaches 40.

[0032] By utilizing the voltage characteristics differences of the actuator's operating states, and through voltage detection and counting accumulation during state switching, it can determine whether there is a short circuit fault in the drive circuit. This enables accurate diagnosis of short circuit faults in the actuator drive circuit, ensuring the reliability of the actuator response. The counting mechanism avoids false alarms caused by transient interference, thus improving diagnostic stability.

[0033] ECU self-diagnostic module: used to detect faults in the ECU's software execution sequence, sensor power supply, clock, memory, watchdog timer, registers, AD conversion, and ignition function; The ECU self-diagnostic module includes: Watchdog diagnostics: Detects whether the ECU software execution sequence times out; Memory diagnostics: Verify the integrity of non-volatile memory data; AD conversion diagnosis: Check whether the accuracy of analog signal conversion is out of tolerance.

[0034] In practice, the watchdog diagnostics detects whether the ECU software execution sequence times out; if it does, a fault flag is triggered. The memory diagnostics verifies the integrity of the non-volatile memory data through checksum comparison. The AD conversion diagnostics checks the accuracy of the analog signal conversion; if the deviation between the voltage sample value and the actual value exceeds a threshold, a fault is triggered.

[0035] By monitoring the operating status of key components inside the ECU, such as software timing, data storage, and signal conversion, and using threshold comparison and verification mechanisms, faults in the ECU itself can be detected, thereby ensuring the stability of the ECU's core functions and preventing system failures caused by internal faults.

[0036] Dynamic enable control module: Dynamically enables or disables the diagnostic process based on battery voltage, engine status, sensor data thresholds, and environmental conditions.

[0037] In practice, the diagnostic process is dynamically activated or disabled based on battery voltage, engine status, sensor data thresholds, and environmental conditions. For example, some diagnostics are disabled when the battery voltage is below 11V to avoid false alarms. By collecting environmental and system parameters in real time and setting enabling conditions, such as voltage range and operating status, the diagnostic process is ensured to run only under reasonable conditions, reducing unnecessary diagnostic consumption. This reduces power consumption, avoids false alarms under abnormal operating conditions, and adapts to different environments, improving diagnostic adaptability.

[0038] Fault determination module: Based on the counter accumulation mechanism, when the fault condition continuously meets the preset counting threshold, the fault flag is triggered, and the diagnostic result is output when the diagnostic counter reaches the completion threshold.

[0039] In practice, based on the counter accumulation mechanism, a fault flag is triggered when the fault condition continuously meets the preset counting threshold (e.g., 320 times), and the diagnostic result is output when the diagnostic counter reaches the completion threshold (e.g., 640 times).

[0040] By filtering out transient interference through cumulative counting, the fault is only confirmed when it persists, thus avoiding false alarms caused by occasional anomalies. This improves the accuracy of fault diagnosis and reduces the false alarm rate.

[0041] Also includes: The "Three Highs" test calibration module is used for dynamic calibration of diagnostic parameters in high-altitude, high-temperature, and high-cold environments, including: Reasonable threshold for pressure sensor correction in high-altitude environments; Calibrate the oil tank pressure cooling time in high-temperature environments.

[0042] In practical implementation, for high-altitude environments: correct the reasonableness threshold of the pressure sensor, such as adjusting the comparison benchmark of the atmospheric pressure sensor.

[0043] High-temperature environment: Adjust the oil tank pressure cooling time calibration to avoid pressure misjudgment caused by high temperature.

[0044] Based on the changes in sensor characteristics under high-altitude, high-temperature, and low-temperature environments, the threshold values ​​of diagnostic parameters are dynamically adjusted to ensure the accuracy of the diagnostic logic, thereby improving the system's adaptability to extreme environments and reducing diagnostic biases caused by environmental factors.

[0045] like Figure 1 As shown, the present invention provides a method for diagnosing the performance of an automotive engine electronic control unit, comprising the following steps: Step S1: Detect engine operating status, battery voltage, and sensor data; Step S2: Dynamically activate the diagnostic process based on preset enabling conditions, including: The battery voltage is in the range of 11V to 16V; The engine is running or ignited; No pending faults were found in the associated sensors; Environmental parameters meet the calibration thresholds; The dynamic enabling conditions further include: Throttle opening is less than the calibrated limit; The engine coolant temperature is higher than the minimum threshold. The vehicle's power-off time exceeds the cooling threshold. Step S3: When the sensor or actuator data exceeds the preset short-circuit threshold, the fault counter is triggered to accumulate; Step S4: If the fault counter reaches the first counting threshold, a fault is determined to have occurred; Step S5: When the diagnostic counter reaches the second counting threshold, the diagnosis is completed and a fault code is output.

[0046] Step S3 further includes: Under deceleration conditions, if the intake pressure exceeds the calibrated maximum value, the rationality fault counter will be triggered. In high-altitude environments, atmospheric pressure correction calibration is dynamically adjusted to avoid false alarms.

[0047] The counting mechanism in step S3 includes: When the fault condition is met, the counter increments by an increment step of (1-3); When the fault condition is not met, the counter decreases by a decrement step size of (3-5). The fault flag is activated when the counter reaches the threshold.

[0048] In practice, a hierarchical detection mechanism is used: first, the system operating conditions (enabling conditions) are confirmed; then, data anomalies are monitored in real time; the duration of the fault is accumulated using a counter; and finally, the fault is confirmed and the result is output. This ensures the comprehensiveness and accuracy of fault detection through a systematic diagnostic process, while the hierarchical counting mechanism avoids instantaneous interference and improves diagnostic reliability.

[0049] In addition to the basic conditions, additional conditions are added, such as throttle opening less than the calibrated limit, engine coolant temperature higher than the minimum threshold, and vehicle power-down time greater than the cooling threshold. For example, some diagnostics are disabled when the throttle opening exceeds 3%. By combining engine operating conditions (such as throttle opening and coolant temperature) and shutdown status, the enabling conditions are further refined to ensure that the diagnostic process only operates under stable conditions. This reduces false alarms under dynamic operating conditions and improves diagnostic accuracy.

[0050] When the fault condition is met, the counter increments by 1-3 steps; when it is not met, it decrements by 3-5 steps. The fault flag is activated when the counter reaches the threshold. For example, in the short-circuit diagnosis of the intake pressure sensor, the increment step is 1 and the decrement step is 3. By using different increment and decrement mechanisms, the sensitivity and anti-interference capability of fault detection are balanced: the increment step ensures rapid accumulation of faults, and the decrement step avoids erroneous retention of the fault flag after interference, thereby improving the response speed of fault detection and reducing the probability of false alarms.

[0051] Specifically, the system acquires real-time parameters from sensors, actuators, and the ECU, and activates the diagnostic process based on conditions such as battery voltage and engine operating conditions to avoid invalid diagnoses. The sensor diagnostic module detects short circuits, rationality, and jamming faults; the actuator diagnostic module detects short circuits in the drive circuit; the ECU self-diagnostic module monitors internal functions, confirms the persistence of faults through a counter accumulation mechanism, and outputs diagnostic results; and the high-altitude, high-temperature, and high-humidity test calibration module dynamically corrects diagnostic parameters under extreme conditions.

[0052] By forming a complete fault detection chain from sensors to actuators and then to the ECU, the entire system link is covered; by using a counting strategy of "incremental accumulation + decremental reduction", transient interference is filtered out to ensure the reliability of fault detection; and the diagnostic threshold is adjusted in real time according to the environment and operating conditions to improve adaptability.

[0053] By using voltage threshold detection, multi-sensor data comparison, and counting accumulation, the false alarm rate is reduced by more than 40%. The high-temperature, high-altitude, and high-temperature test calibration module enables the system to maintain diagnostic accuracy in environments ranging from -40℃ to 125℃ and altitudes above 5000 meters. The ECU self-diagnostic module monitors internal faults in real time to avoid vehicle function failures caused by ECU malfunctions. Dynamic enable control reduces unnecessary diagnostics and lowers ECU power consumption by approximately 15%.

[0054] Through a systematic hardware diagnostic architecture and intelligent software algorithms, efficient and accurate fault detection of the engine electronic control unit is achieved, providing technical assurance for the reliability of the vehicle power system.

[0055] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A performance diagnostic system for an automotive engine electronic control unit, characterized in that, include: Sensor diagnostic module: used to diagnose short circuits, malfunctions, interference, and jamming faults in intake pressure sensors, boost pressure sensors, atmospheric pressure sensors, temperature sensors, and position sensors; Actuator diagnostic module: used to diagnose short-circuit faults in the output drive circuits of fault lights, fans, canister solenoid valves, fuel injectors, and relays; ECU self-diagnostic module: used to detect faults in the ECU's software execution sequence, sensor power supply, clock, memory, watchdog timer, registers, AD conversion, and ignition function; Dynamic enable control module: dynamically enables or disables the diagnostic process based on battery voltage, engine status, sensor data thresholds, and environmental conditions; Fault determination module: Based on the counter accumulation mechanism, when the fault condition continuously meets the preset counting threshold, the fault flag is triggered, and the diagnostic result is output when the diagnostic counter reaches the completion threshold.

2. The automotive engine electronic control unit performance diagnostic system according to claim 1, characterized in that, The sensor diagnostic module includes: Short circuit diagnostic unit: detects whether the sensor voltage exceeds a preset threshold and determines the fault based on the accumulated result of the fault counter; Reasonableness diagnostic unit: Under idling or driving conditions, whether the difference between the data from multiple sensors exceeds the calibrated tolerance range; Stuck diagnostic unit: During engine operation, it detects whether the change in sensor data is below the dynamic threshold.

3. The automotive engine electronic control unit performance diagnostic system according to claim 1, characterized in that, The actuator diagnostic module includes: Dual-state diagnostic logic: Detects short-circuit faults to the power supply when the actuator is on, and detects short-circuit faults to ground when the actuator is off; Counting accumulation mechanism: When the fault continues, the counter accumulates with an increment step size; when the fault disappears, it decreases with a decrement step size.

4. The automotive engine electronic control unit performance diagnostic system according to claim 1, characterized in that, The ECU self-diagnostic module includes: Watchdog diagnostics: Detects whether the ECU software execution sequence times out; Memory diagnostics: Verify the integrity of non-volatile memory data; AD conversion diagnosis: Check whether the accuracy of analog signal conversion is out of tolerance.

5. The automotive engine electronic control unit performance diagnostic system according to claim 1, characterized in that, Also includes: The "Three Highs" test calibration module is used for dynamic calibration of diagnostic parameters in high-altitude, high-temperature, and high-cold environments, including: Reasonable threshold for pressure sensor correction in high-altitude environments; Calibrate the oil tank pressure cooling time in high-temperature environments.

6. A method for diagnosing the performance of an automotive engine electronic control unit, characterized in that, Includes the following steps: Step S1: Detect engine operating status, battery voltage, and sensor data; Step S2: Dynamically activate the diagnostic process based on preset enabling conditions, including: The battery voltage is in the range of 11V to 16V; The engine is running or ignited; No pending faults were found in the associated sensors; Environmental parameters meet the calibration thresholds; Step S3: When the sensor or actuator data exceeds the preset short-circuit threshold, the fault counter is triggered to accumulate; Step S4: If the fault counter reaches the first counting threshold, a fault is determined to have occurred; Step S5: When the diagnostic counter reaches the second counting threshold, the diagnosis is completed and a fault code is output.

7. The automotive engine electronic control unit performance diagnostic system and method according to claim 6, characterized in that, Step S3 further includes: Under deceleration conditions, if the intake pressure exceeds the calibrated maximum value, the rationality fault counter will be triggered. In high-altitude environments, atmospheric pressure correction calibration is dynamically adjusted to avoid false alarms.

8. The automotive engine electronic control unit performance diagnostic system and method according to claim 6, characterized in that, The dynamic enabling conditions further include: Throttle opening is less than the calibrated limit; The engine coolant temperature is higher than the minimum threshold. The vehicle's power-off time exceeds the cooling threshold.

9. The automotive engine electronic control unit performance diagnostic system and method according to claim 6, characterized in that, The counting mechanism in step S3 includes: When the fault condition is met, the counter increments by an increment step of (1-3); When the fault condition is not met, the counter decreases by a decrement step size of (3-5); The fault flag is activated when the counter reaches the threshold.

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