A vehicle-mounted controller FCT automatic test equipment

Abstract

The utility model relates to vehicle control ware test technical field, concretely is a kind of vehicle control ware FCT automation test device, contain automation test platform and multifunctional test system, automation test platform is realized controller automatic feeding and discharging by linear slide module group drive pneumatic fixture, adjustable test needle bed is compatible with different size controller interface, multifunctional test system integrates programmable power array analog storage battery fluctuation, high-precision acquisition module synchronous acquisition multichannel signal, multi-protocol communication unit resolves CAN FD / SENT data, load simulation and fault injection unit test driving ability and abnormal working condition. Host system executes test sequence by industrial computer, and scanning code gun is associated serial number and test data, realizes whole-process automation test. The equipment supports dynamic power test, signal synergy analysis and communication reliability verification, single-piece test time is not more than forty-five seconds, significantly improves test efficiency and quality consistency.

Description

Technical Field

[0001] This utility model relates to the field of vehicle controller testing technology, specifically an automated testing device for vehicle controller FCT. Background Technology

[0002] In the field of automotive electronics, the vehicle controller refers to the electronic control unit used to monitor, manage and control the operation of various subsystems of a vehicle. Its core function is to collect data through sensors, execute algorithm logic and output control commands to ensure the safe and efficient operation of the vehicle.

[0003] Existing vehicle controller off-line testing mostly uses semi-automatic test benches, which have the following drawbacks:

[0004] Low testing efficiency: Manual insertion and removal of the device under test and switching of test items result in long test times per test;

[0005] Incomplete test coverage: Only basic communication functions were verified, lacking in-depth testing of high-side drive load capacity, SENT signal real-time performance, and abnormal operating condition simulation.

[0006] Poor consistency: Manual operation leads to deviations in test parameters, making it impossible to guarantee the consistency of batch product quality.

[0007] In view of the above-mentioned problems, this technical solution designs an automated testing device for vehicle-mounted controller FCT. Utility Model Content

[0008] The purpose of this invention is to provide an automated testing device for vehicle-mounted controllers (FCT) to solve the problems mentioned in the background art.

[0009] To achieve the above objectives, this utility model provides the following technical solution:

[0010] An automated testing device for vehicle-mounted controller FCT, comprising:

[0011] Automated testing platform:

[0012] A linear slide module driven by a servo motor integrates pneumatic clamps to enable automatic loading / unloading of materials by the vehicle controller.

[0013] Adjustable test bed with pneumatic floating probe module, compatible with controller interfaces of different sizes;

[0014] Multifunctional testing system:

[0015] Programmable power supply array: Provides 0-40V / 0-50A adjustable power supply to simulate vehicle battery voltage fluctuations;

[0016] High-precision acquisition module: Simultaneously acquires 16 channels of analog signals with ±0.1% accuracy and 32 channels of digital signals;

[0017] Multi-protocol communication unit: Integrated dual-channel CAN FD supports 500k-5Mbps, SENT decoder meets SAE J2716 standard;

[0018] Load simulation and fault injection unit: Programmable electronic load: Simulates 0.1Ω-10kΩ resistive / inductive loads to test high-side drive capability;

[0019] Fault injection circuit: can inject abnormal operating conditions such as short circuit, open circuit, and signal jitter;

[0020] Main control system: Industrial control computer running test sequence management software;

[0021] The data storage module records the original test waveforms and judgment results;

[0022] The barcode scanner is associated with the vehicle controller serial number and test data.

[0023] The specific testing process is as follows: the barcode scanner enters the vehicle controller serial number, then the linear slide module grabs the vehicle controller onto the adjustable test needle bed, and then the pneumatic clamp presses it in place;

[0024] The main control system executes the following sequence: power characteristic test, followed by switch response, and CAN / SENT communication for fault injection test through high-side load capability.

[0025] Real-time data collection is compared with standard parameters, and the results are stored in the database.

[0026] Compared with the prior art, the beneficial effects of this utility model are:

[0027] The automatic loading and unloading of materials via linear slides and the unmanned operation of the entire process reduce the testing time for a single piece.

[0028] The voltage withstand stability of the controller was verified by simulating battery voltage fluctuations using a programmable power supply array.

[0029] The high-side drive capability is quantified by the load simulation unit, and the fault injection unit supports short-circuit / open-circuit / load-drop pulse testing.

[0030] A high-precision acquisition module ensures data consistency, and a data storage module stores the original waveforms with associated serial numbers, supporting process deviation early warning and historical traceability.

[0031] The temperature rise monitoring module records the temperature of power devices in real time to prevent overheating failure and ensure quality. Attached Figure Description

[0032] Fig. 1This is a simplified structural diagram of an automated testing device for vehicle-mounted controllers (FCT).

[0033] Fig. 2 This is an architecture diagram of an automated testing equipment for vehicle-mounted controllers (FCT).

[0034] Among them: linear slide module 101, pneumatic fixture 102, and adjustable test needle bed 103. Detailed Implementation

[0035] It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0036] In the description of this utility model, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more.

[0037] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0038] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0039] Please see Figs. 1-2 An automated testing device for vehicle-mounted controller FCT, comprising:

[0040] Automated testing platform:

[0041] A linear slide module 101 driven by a servo motor integrates a pneumatic clamp 102 to realize automatic loading / unloading of the vehicle controller;

[0042] The adjustable test bed 103 is equipped with a pneumatic floating probe module and is compatible with controller interfaces of different sizes.

[0043] Multifunctional testing system:

[0044] Programmable power supply array: Provides 0-40V / 0-50A adjustable power supply to simulate vehicle battery voltage fluctuations;

[0045] High-precision acquisition module: Simultaneously acquires 16 channels of analog signals with ±0.1% accuracy and 32 channels of digital signals;

[0046] Multi-protocol communication unit: Integrated dual-channel CAN FD supports 500k-5Mbps, SENT decoder meets SAE J2716 standard;

[0047] Load simulation and fault injection unit:

[0048] Programmable electronic load: Simulates 0.1Ω-10kΩ resistive / inductive loads to test high-side drive capability;

[0049] Fault injection circuit: can inject abnormal operating conditions such as short circuit, open circuit, and signal jitter;

[0050] Main control system:

[0051] Industrial control computer running test sequence management software;

[0052] The data storage module records the original test waveforms and judgment results;

[0053] The barcode scanner is associated with the vehicle controller serial number and test data.

[0054] The specific testing process is as follows: the barcode scanner enters the vehicle controller serial number, then the linear slide module 101 grabs the vehicle controller to the adjustable test needle bed 103, and then the pneumatic clamp 102 presses it in place.

[0055] The main control system executes the following sequence: power characteristic test, followed by switch response, and CAN / SENT communication for fault injection test through high-side load capability.

[0056] Real-time data collection is compared with standard parameters, and the results are stored in the database.

[0057] In this embodiment of the invention, the specific structure of the linear slide module 101, the pneumatic clamp 102, and the adjustable test needle bed 103, as well as their interconnection, can all be understood and implemented with the help of existing related technologies, and will not be described in detail or limited here.

[0058] The programmable power supply array consists of four parallel DC power supply modules, equipped with a multi-stage LC filter circuit and a MOSFET switch array, enabling it to support 0-40V / 0-50A output (accuracy ±0.1%) and transient response time <100μs.

[0059] The high-precision acquisition module includes 16 independent signal conditioning circuits, which integrate a programmable gain amplifier (PGA) and an anti-aliasing filter. It uses a 24-bit ADC to acquire analog signals, has 32 optocoupler-isolated digital input channels, and supports 1MHz high-speed sampling.

[0060] The multi-protocol communication unit is based on an FPGA hardware-accelerated protocol stack, integrates dual CAN FD interfaces, and is compatible with 5Mbps rate and SENT decoder. The SENT signal channel is equipped with a hysteresis comparator and noise suppression circuit.

[0061] The vehicle controller under test is connected to the system through the adjustable test bed 103. The programmable power supply array supplies power to the vehicle controller and dynamically simulates the voltage fluctuation of the vehicle battery. The IO signal of the vehicle controller is sent to the high-precision acquisition module for synchronous acquisition. The CAN / SENT communication signal is transmitted to the multi-protocol communication unit for protocol parsing. Then the acquired data and communication decoding results are uploaded to the main control system for processing in real time.

[0062] By simulating scenarios such as vehicle start-stop voltage step (9V→16V) and battery slow-down, the voltage withstand stability and overcurrent protection response of the controller are verified, and dynamic power supply testing is achieved.

[0063] Time-aligned acquisition of digital and analog signals is performed to analyze signal compatibility.

[0064] The above applies to digital quantities, such as PWM duty cycle; and analog quantities, such as temperature sensor output.

[0065] Among them, abnormal frames such as CRC error and bit stuffing error are injected into CAN FD, and the monitoring controller retransmission mechanism is used;

[0066] SENT checks the fast channel CRC and measures frame period jitter to verify the reliability of communication.

[0067] In one embodiment of the present invention, the programmable electronic load uses a combination of a power MOSFET matrix and a precision current sampling resistor to support resistive loads of 0.1Ω-10kΩ with a resolution of 0.01Ω and inductive loads of 1μH-10mH, in conjunction with a wind-cooling system.

[0068] The fault injection circuit is controlled by a relay matrix to switch fault types, including short circuit / open circuit / signal jitter, and also integrates a high-voltage pulse generator to support the generation of ISO 7637-2 standard load dump pulses;

[0069] The high-voltage pulse generator includes: energy storage capacitor + IGBT switch, and load dump pulse such as: 100V / 2Ω pulse width 400ms.

[0070] The load simulation and fault injection unit also includes a temperature rise monitoring module, which includes a non-contact infrared thermal imager and a 4-channel spring probe integrated thermocouple.

[0071] The high-side output of the vehicle controller under test is connected to the programmable electronic load. The load current is fed back to the high-precision acquisition module. The fault injection circuit forces a short-circuit / open-circuit signal to the output of the vehicle controller through a relay matrix. At the same time, the temperature rise monitoring module collects the temperature data of the power devices of the vehicle controller in real time and uploads it to the main control system.

[0072] By increasing the load current in steps, such as 0.5A to 5A, and plotting the output voltage-current curve, the overload point of the driver transistor can be determined, thus quantifying the driving capability.

[0073] The overcurrent protection action time is detected by momentarily grounding the output terminal;

[0074] Generate ISO 7637-2 standard pulses (5a / 5b) to verify the clamping capability of the TVS device and perform load dump testing:

[0075] Then, it was continuously operated under maximum load, and the MOSFET temperature rise curve was recorded synchronously by an infrared thermal imager and a thermocouple.

[0076] As a preferred embodiment of the present invention

[0077] The industrial control computer is equipped with an Intel i7 processor, 16GB of RAM, and a PCIe expansion slot, and runs test sequence management software.

[0078] The data storage module uses 1TB NVMe SSDs (read / write speed 3.5GB / s) to form RAID 1 redundant storage;

[0079] The main control system also includes a motion control card, which is based on the EtherCAT bus and has a synchronization cycle of ≤1ms. It uses FPGA to realize the multi-axis linkage of the linear slide module 101.

[0080] The barcode scanner connects directly to the industrial control computer via USB through a laser barcode recognition device.

[0081] The barcode scanner enters the vehicle controller serial number, triggering the test process. The industrial computer drives the linear slide module 101 to grab the vehicle controller onto the needle bed via the motion control card.

[0082] The main control system consists of a programmable power supply array, a high-precision acquisition module, a multi-protocol communication unit, and a load simulation and fault injection unit working together in a preset sequence.

[0083] Raw test data is stored in the data module, and a judgment report is automatically generated.

[0084] Raw test data typically refers to waveforms and temperatures.

[0085] The entire process of vehicle controller operation, from loading and electrical testing to unloading, is unmanned, with a single-piece testing time of ≤45 seconds, achieving full automation.

[0086] By comparing test data with standard parameter libraries in real time and statistically analyzing the parameter distribution of batch products, early warnings of process deviations can be issued.

[0087] The original waveform is stored by associating it with the vehicle controller serial number, which supports historical data retrieval and quality analysis.

[0088] The working principle of this utility model is as follows: In the idle position of this device, all the aforementioned driving components (representing power elements, electrical devices, and compatible power supplies) are connected via wires. The electrical connections are completed in sequence between the working components. The detailed connection methods are well-known in the field. The following mainly describes the working principle and process, without further explanation of the electrical control.

[0089] Initialization: The barcode scanner enters the controller serial number, triggering the test process;

[0090] Feeding: The linear slide module 101 drives the pneumatic clamp 102 to grab the vehicle controller to the adjustable test needle bed 103, and the pneumatic clamp 102 presses it in place;

[0091] Collaborative testing: The main control system activates each module according to a preset sequence:

[0092] Power supply testing: Programmable power supply array simulates the voltage step during vehicle start-stop.

[0093] Signal acquisition: The high-precision acquisition module simultaneously acquires 16 analog signals and 32 digital signals;

[0094] Communication verification: Inject CAN FD error frames into the multi-protocol communication unit and monitor SENT frame period jitter;

[0095] Load test: Increase the current in a stepwise manner with an electronic load and plot the VI curve of the drive transistor;

[0096] Fault injection: The relay matrix is ​​forced to short-circuit / open-circuit, and the high-voltage pulse generator generates an ISO 7637-2 load dump pulse;

[0097] Judgment storage: Real-time data is compared with standard parameters, and the original waveform and judgment result are associated with the sequence number and stored in the database;

[0098] Material unloading: After the test is completed, the slide module is removed from the vehicle controller.

[0099] It should be understood that in this application, all rotating, sliding, meshing, belt-driven and other moving parts are well lubricated and not prone to slippage or wear, and each part is provided with a corresponding protective shell. However, in the accompanying drawings of this application, the connection state of each moving part is not shown. It should also be understood that all parts in this application are made of metal or plastic materials with suitable strength in the relevant field to ensure that their structural rigidity meets the actual requirements.

[0100] The preferred embodiments of the present invention have been described in detail above. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. An automated testing device for vehicle-mounted controller FCT, characterized in that, include: Automated testing platform: includes a linear slide module (101), a pneumatic fixture (102) and an adjustable test needle bed (103). The linear slide module (101) drives the pneumatic fixture (102) to realize automatic loading and unloading of the controller. The adjustable test needle bed (103) is equipped with a pneumatic floating probe module to be compatible with controllers of different sizes. Multifunctional test system: integrates programmable power supply array, high-precision acquisition module, and multi-protocol communication unit; Load simulation and fault injection unit; programmable electronic load, fault injection circuit, temperature rise monitoring module; Main control system: includes industrial control computer, data storage module and barcode scanner; The programmable power supply array consists of parallel DC power modules, equipped with multi-stage LC filter circuits and MOSFET switch arrays.

2. The FCT automated testing equipment for load controllers according to claim 1, characterized in that, The high-precision acquisition module includes: 16 independent signal conditioning circuits, an integrated programmable gain amplifier and anti-aliasing filter, and a 24-bit ADC for acquiring analog signals; and 32 optocoupler-isolated digital input channels.

3. The FCT automated testing equipment for load controllers according to claim 1, characterized in that, The multi-protocol communication unit is based on an FPGA hardware-accelerated protocol stack and integrates dual CAN FD interfaces and a SENT decoder.

4. The FCT automated testing equipment for load controllers according to claim 1, characterized in that, The programmable electronic load employs a power MOSFET matrix and a precision current sampling resistor; The fault injection circuit includes a relay matrix to control short circuit / open circuit / signal jitter, and a high-voltage pulse generator to generate ISO 7637-2 load dump pulses; The temperature rise monitoring module includes a non-contact infrared thermal imager and a four-channel spring probe integrated thermocouple.

5. The FCT automated testing equipment for load controllers according to claim 1, characterized in that, The main control system drives the linear slide module (101) through a motion control card; the data storage module uses NVMe SSDs to form RAID 1 redundant storage.

Images