A fault testing system and apparatus

Abstract

The application provides a fault test system and device, which is applied to the technical field of electrical equipment detection, and comprises a fault injection module and a control module. The fault injection module comprises a plurality of first test circuits, and the plurality of first test circuits are connected with a vehicle controller respectively. The control module is connected with the controlled ends of the plurality of first test circuits, and is configured to control at least one first test circuit in the plurality of first test circuits to act, and switch the fault simulation mode of the fault injection module. The fault test system can automatically realize fault simulation of a single wire harness and a plurality of wire harnesses, without manual operation, so that the operation steps are simplified, the test data is prevented from being affected by human subjective factors, and the comprehensiveness and reliability of performance test of the vehicle controller under different wire harness fault scenes are improved.

Description

Technical Field

[0001] This application relates to the field of electrical equipment testing technology, and in particular to a fault testing system and equipment. Background Technology

[0002] The vehicle controller is a core component of vehicle power control, and its performance directly determines the safety and reliability of vehicle operation. Currently, wiring harness fault testing of the vehicle controller still largely relies on traditional manual operation. The testing process is cumbersome, the steps are highly repetitive, it is time-consuming, and the test results are easily affected by human factors. At the same time, traditional testing equipment also has the problem of limited testing range for complex fault scenarios. Utility Model Content

[0003] This application provides a fault testing system and equipment, which aims to solve the problems of incomplete detection and insufficient detection accuracy of vehicle controllers in related technologies.

[0004] Firstly, a fault testing system is provided for use in a vehicle, the vehicle including a vehicle controller. The fault testing system includes a fault injection module and a control module. The fault injection module includes multiple first test circuits, each connected to the vehicle controller. The control module is connected to the controlled terminals of the multiple first test circuits and is configured to control the operation of at least one of the multiple first test circuits to switch the fault simulation mode of the fault injection module. The fault simulation mode includes at least fault simulation of a single wiring harness and fault simulation of multiple wiring harnesses.

[0005] Based on the above approach, in the fault testing system provided in this application, multiple first test circuits of the fault injection module are connected one-to-one with the wiring harness under test of the vehicle controller. The control module can independently control the operation of a single first test circuit to simulate the fault of the corresponding wiring harness, thus achieving accurate testing of a single wiring harness fault scenario. The control module can also control at least two first test circuits to operate simultaneously to simulate the fault of the corresponding wiring harness, thus achieving accurate testing of a multi-wiring harness fault scenario. By controlling the operation of different numbers of first test circuits, the control module can flexibly switch between and test single-wiring harness and multi-wiring harness fault scenarios, covering a comprehensive range of wiring harness fault testing scenarios. Furthermore, this fault testing system can automate the operation process of different fault injections through the control module, eliminating the need for manual operation as in related technologies, reducing operational steps. Moreover, automated testing eliminates the need for manual wiring harness connection, fault state switching, and test data recording, ensuring the testing process is unaffected by subjective human factors, resulting in higher testing accuracy and reliability, further supporting the reliability of the vehicle controller.

[0006] In one possible design, each first test circuit includes: a first simulation unit. The controlled terminal of the first simulation unit serves as the controlled terminal of the first test circuit and is connected to the control module. The input terminal of the first simulation unit is connected to the wiring harness under test of the vehicle controller. The output terminal of the first simulation unit is selectively connected to a normal simulation node or a fault simulation node; wherein, the fault simulation nodes of multiple first simulation units are connected together.

[0007] Based on the above approach, the fault testing system provided in this application connects one-to-one with the wiring harness under test through a first simulation unit. The output of the first simulation unit can be selectively connected to either a normal simulation node or a fault simulation node, enabling flexible switching between normal and fault states for a single wiring harness and ensuring the independence and accuracy of fault simulation for each harness. Simultaneously, the fault simulation nodes of multiple first simulation units can be interconnected, allowing the control module to simulate faults in multiple wiring harnesses, covering line-to-line fault testing scenarios. The control module can automatically and flexibly switch the connection objects at the output of each first fault simulation unit to achieve flexible switching between fault testing scenarios corresponding to one or more wiring harnesses. This improves the flexibility of fault switching and testing in the fault testing system provided in this application. The testing process requires no manual intervention, the testing steps are simpler, and the testing process is unaffected by human factors, resulting in higher testing accuracy and further supporting the effective verification of the wiring harness performance of the vehicle controller.

[0008] In one possible design, the first simulation unit includes a first relay, which includes a first coil and a first switch; one end of the first coil serves as the controlled end of the first simulation unit and is connected to the control module, the other end of the first coil is connected to the power supply, the common end of the first switch serves as the input end of the first simulation unit and is connected to the wiring harness under test of the vehicle controller, the first switching end of the first switch is connected to the normal simulation node, and the second switching end of the first switch is connected to the fault simulation node.

[0009] Based on the above approach, in the fault testing system provided in this application, the first simulation unit uses a first relay, which drives the first switch action through the first coil, realizing accurate switching between the normal state simulation and the fault state simulation of the wiring harness under test, ensuring the reliability of the fault simulation test of a single wiring harness. Furthermore, the relay's hardware on / off logic has strong anti-interference capabilities, avoiding environmental interference and better reflecting the physical connection characteristics of wiring harnesses in the actual vehicle environment, thus improving the effectiveness and accuracy of fault simulation switching and testing based on this relay. When multiple wiring harnesses' corresponding fault simulation nodes are interconnected, combined with the control of the relay action, multiple wiring harness faults can be simulated. Simultaneously, the control module's flexible control of the first coil's on / off action enhances the testing flexibility and further improves the stability and comprehensiveness of the vehicle controller wiring harness fault testing.

[0010] In one possible design, the fault testing system further includes a second test circuit. The controlled terminal of the second test circuit is connected to the control module, the input terminal of the second test circuit is connected to the fault simulation node, and the output terminal of the second test circuit is selectively grounded or open-circuited; wherein, the fault simulation mode also includes a short-circuit fault simulation to ground.

[0011] Based on the above approach, the fault testing system provided in this application connects to the fault simulation node via a second test circuit, enabling the system to simulate ground short-circuit faults and enriching the test types for vehicle controller wiring harness faults. Secondly, by sharing the fault simulation node, the control module can control the operation of multiple first test circuits to simultaneously connect multiple wiring harnesses to the fault simulation node, simulating ground short-circuit faults simultaneously via the second test circuit. Furthermore, the control module can flexibly switch the output state of the second test circuit to achieve rapid switching between ground short-circuit faults and other fault modes, making fault testing more flexible. This process requires no manual operation; the control module can automatically control the actions of the first and second test circuits, simplifying the testing process and ensuring that the test results are not affected by subjective factors, resulting in higher test accuracy and further improving the completeness of wiring harness fault testing for vehicle controllers.

[0012] In one possible design, the second test circuit includes a second relay, which includes a second coil and a second switch; one end of the second coil serves as the controlled end of the second test circuit and is connected to the control module, the other end of the second coil is connected to the power supply, the common end of the second switch serves as the input end of the second test circuit and is connected to the fault simulation node, the first switching end of the second switch is grounded, and the second switching end of the second switch is configured to be in an open circuit state.

[0013] Based on the above method, the control module in the fault testing system provided in this application controls the operation of the second coil of the second test circuit to ground or open the second switch, thereby enabling flexible switching between short-circuit to ground and open-circuit fault testing of the vehicle controller wiring harness and ensuring the reliability of the short-circuit to ground fault simulation of the fault testing system. Furthermore, by controlling the open-circuit state of the second test circuit and the control logic of the first test circuit, the control module can also perform open-circuit fault testing of a single wiring harness, allowing the fault testing system to flexibly switch fault injection modes and improving the effectiveness of wiring harness fault testing of the vehicle controller.

[0014] In one possible design, the fault testing system further includes a third test circuit. The controlled terminal of the third test circuit is connected to the control module, the input terminal of the third test circuit is connected to the fault simulation node, and the output terminal of the third test circuit is selectively connected to the power supply simulation node or an open circuit; wherein, the fault simulation mode also includes simulation of power supply short-circuit faults.

[0015] Based on the above approach, the fault testing system provided in this application enables the simulation testing of power supply short-circuit faults by setting up a third test circuit and connecting it to a fault simulation node. Each test circuit shares a fault simulation node, allowing the control module to collaboratively control the actions of multiple first test circuits to simulate power supply short-circuit faults in multiple wiring harnesses. By switching the output state of the third test circuit, the control module allows the fault testing system to flexibly switch the fault injection mode of the wiring harness, enabling it to simulate power supply short-circuit faults or switch to other fault modes. This results in more comprehensive fault type coverage. Furthermore, this flexible switching of fault injection modes requires no manual operation, reducing testing steps, and the test results are not affected by subjective factors, leading to higher accuracy and further improving the comprehensiveness and reliability of vehicle controller wiring harness fault testing.

[0016] In one possible design, the third test circuit includes a third relay, which includes a third coil and a third switch; one end of the third coil serves as the controlled end of the third test circuit and is connected to the control module, the other end of the third coil is connected to the power supply, the common end of the third switch serves as the input end of the third test circuit and is connected to the fault simulation node, the first switching end of the third switch is connected to the power supply simulation node, and the second switching end of the third switch is configured to be in an open circuit state.

[0017] Based on the above method, the control module of the fault testing system provided in this application can control the third relay in the third test circuit to be energized, so that the third coil drives the third switch to select the power supply. This enables the fault testing system to simulate power supply short-circuit faults. The use of relay hardware switching also ensures the reliability of the wiring harness's simulation of power supply short-circuit faults. The control module can control the operation of the first test circuit corresponding to multiple wiring harnesses under test. Combined with the shared design of fault simulation nodes, it can realize the simultaneous simulation of power supply short-circuit faults for multiple wiring harnesses, further improving the fault test types of the fault testing system and effectively supporting the comprehensiveness of wiring harness fault testing for the vehicle controller.

[0018] In one possible design, the fault testing system further includes a fourth test circuit and a fifth test circuit. The fourth test circuit includes a fourth relay, which includes a fourth coil and a fourth switch. One end of the fourth coil is connected to the control module. The first common terminal of the fourth switch is connected to the fault simulation node. The second common terminal of the fourth switch is connected to the power supply. The first switching terminal of the fourth switch is configured as an open circuit. The second switching terminal of the fourth switch is grounded. The third switching terminal of the fourth switch is configured as an open circuit. The fifth test circuit includes a fifth relay, which includes a fifth coil and a fifth switch. One end of the fifth coil is connected to the control module. The other end of the fifth coil is connected to the fourth switching terminal of the fourth switch. The first common terminal of the fifth switch is connected to both the first common terminal of the fourth switch and the fault simulation node. The second common terminal is connected to the power supply. The first switching terminal of the fifth switch is configured as an open circuit. The second switching terminal of the fifth switch is connected to the power supply simulation node. The third switching terminal of the fifth switch is configured as an open circuit. The fourth switching terminal of the fifth switch is connected to the other end of the fourth coil. The fault simulation mode also includes a ground short circuit fault simulation and a power supply short circuit fault simulation. In the ground short circuit fault simulation, the first common terminal of the fourth switch is connected to the second switching terminal of the fourth switch, and the second common terminal of the fourth switch is connected to the third switching terminal of the fourth switch. In the power supply short circuit fault simulation, the first common terminal of the fifth switch is connected to the second switching terminal of the fifth switch, and the second common terminal of the fifth switch is connected to the third switching terminal of the fifth switch.

[0019] Based on the above method, in the fault testing system provided in this application, the fourth and fifth test circuits are cross-connected through the fourth and fifth switches, completely avoiding the simultaneous triggering of both ground short circuit and power short circuit fault modes at the hardware level. This effectively prevents the circuit from experiencing overcurrent or burnout due to the superposition of the two short circuit faults, ensuring the electrical safety and equipment stability of the fault simulation testing process. Furthermore, for the fault testing needs of a single wire harness, the control module can precisely control the operation of the first test circuit corresponding to the wire harness under test, connecting the first test circuit to the fault simulation node, and simultaneously driving the fourth or fifth relay to operate. Through the fourth or fifth test circuit, the ground short circuit fault simulation or the power short circuit fault simulation of a single wire harness can be achieved respectively. For the fault testing needs of multiple wire harnesses, the control module can control the connection of the first test circuits corresponding to multiple wire harnesses under test to the fault simulation node, and then control the operation of the fourth or fifth relay, enabling multiple wire harnesses to simultaneously achieve ground short circuit or power short circuit fault simulation through a shared fault simulation node. By automating the operation of the fourth and fifth test circuits through the control module, not only is the accuracy of simulating faults of different numbers of wiring harnesses ensured, but manual operation is also eliminated, and the triggering logic of complex fault scenarios is simplified. While improving the ease of operation, the test reliability of the fault test system is further improved, and the efficiency of the vehicle controller wiring harness fault test is enhanced.

[0020] In one possible design, the fault testing system further includes a first connection module and a second connection module. A first end of the first connection module is connected to the control module, and a second end of the first connection module is connected to the fault injection module; a first end of the second connection module is connected to the fault injection module, and a second end of the second connection module is connected to the vehicle controller.

[0021] Based on the above approach, the fault testing system provided in this application establishes a stable signal path between the control module and the fault injection module through the first connection module, ensuring accurate transmission of control commands. Simultaneously, the modular connection enhances the convenience of module disassembly, assembly, and maintenance. The second connection module establishes a physical connection between the fault injection module and the vehicle controller, ensuring signal interaction for fault injection and enhancing the compatibility of the fault testing system with vehicle controllers of different interface specifications. This further improves the practicality and adaptability of the fault testing system, providing reliable connection support for the stable conduct of fault simulation tests.

[0022] Secondly, a fault testing device is provided, which includes the fault testing system described in any optional embodiment of the first aspect. This fault testing system can perform comprehensive wiring harness fault simulation testing for the vehicle controller. Attached Figure Description

[0023] Figure 1This is a schematic diagram of the framework structure of a fault testing system of related technology provided in an embodiment of this application; Figure 2 This is a schematic diagram of the framework structure of a fault testing system provided in an embodiment of this application; Figure 3 This is a schematic diagram of the framework structure of another fault testing system provided in the embodiments of this application; Figure 4 This is a schematic diagram of the circuit structure of a fault testing system provided in an embodiment of this application; Figure 5 This is a schematic diagram of the framework structure of another fault testing system provided in the embodiments of this application; Figure 6 This is a schematic diagram of the circuit structure of another fault testing system provided in the embodiments of this application; Figure 7 This is a schematic diagram of the framework structure of another fault testing system provided in an embodiment of this application; Figure 8 This is a schematic diagram of the circuit structure of another fault testing system provided in the embodiments of this application; Figure 9 This is a schematic diagram of the circuit structure of another fault testing system provided in an embodiment of this application; Figure 10 This is a schematic diagram of the framework structure of another fault testing system provided in an embodiment of this application; Figure 11 This is a flowchart illustrating a control method for a fault testing system provided in an embodiment of this application.

[0024] In the attached figures, the following labels are used: 1. Vehicle controller; 2. Fault testing system; 21. Fault injection module; 211. First test circuit; 2111. First simulation unit; 212. Second test circuit; 213. Third test circuit; 214. Fourth test circuit; 215. Fifth test circuit; 22. Control module; a1, Normal simulation node; a2, Normal simulation node; a3, Normal simulation node; b, Fault simulation node; c, Power supply simulation node; Vdd, Power supply; LS1, First relay; LS2, Second relay; LS3, Third relay; LS4, Fourth relay; LS5, Fifth relay; L1, First coil; L2, Second coil; L3, Third coil; L4, Fourth coil; L5, Fifth coil; K1, First switch; K2, Second switch; K3, Third switch; K4, Fourth switch; K5, Fifth switch. Detailed Implementation

[0025] The technical solutions in this application will be clearly and thoroughly described below with reference to the accompanying drawings. In the description of the embodiments of this application, unless otherwise stated, " / " means "or," for example, A / B can mean A or B. "And / or" in the text is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Furthermore, in the description of the embodiments of this application, "multiple" refers to two or more than two.

[0026] Hereinafter, the terms "first" and "second" are used for descriptive purposes only and should not be construed as implying or suggesting relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature.

[0027] The Vehicle Control Unit (VCU), as the core control component that coordinates vehicle power output, energy management, and operating condition coordination, directly determines the vehicle's driving safety, power performance, and functional integrity through its operational stability and signal transmission reliability. It is a crucial link in modern automotive electronic systems that ensures the smooth operation of the entire vehicle. With the continuous improvement of vehicle electrification and intelligence, the number of wiring harnesses connected to the VCU has increased significantly, and the signal interaction logic has become increasingly complex. Comprehensive verification of wiring harness faults has become a core testing step before mass production of the VCU.

[0028] Currently, wiring harness fault testing for vehicle controllers still predominantly employs traditional manual operation methods. During testing, personnel must manually connect the wiring harness, switch fault states, and record test data. This process is cumbersome and involves highly repetitive steps. Furthermore, a single test cycle often takes several hours, making it difficult to meet the efficient verification requirements of mass production. Simultaneously, test results are highly dependent on the operator's experience and adherence to operational procedures, and are prone to deviations due to human factors such as wiring errors and oversights in state switching, resulting in difficulties in ensuring test consistency and accuracy.

[0029] In addition, the functional limitations of traditional wiring harness fault testing equipment result in insufficient simulation coverage of complex fault scenarios such as open circuits, short circuits, and poor contact. It is unable to fully reproduce abnormal wiring harness conditions that may occur during vehicle operation, and it is difficult to meet the stringent requirements of modern automotive electronic systems for the completeness of vehicle controller testing.

[0030] To this end, this application provides a fault testing system and equipment. The fault testing system can automatically simulate faults in a single wiring harness or multiple wiring harnesses of the vehicle controller without manual operation. This simplifies the operation steps and avoids the influence of human subjective factors on the test data, thereby improving the comprehensiveness and reliability of the performance test of the vehicle controller under different wiring harness fault scenarios.

[0031] The following description, in conjunction with the accompanying drawings, provides an exemplary description of the testing system and equipment provided in the embodiments of this application.

[0032] This application provides a fault testing device, such as... Figure 1 As shown, the fault testing equipment provided in this application is used to test the wiring harness performance of the vehicle controller 1. The vehicle controller 1 is a core control component for key functions such as energy management, power control, and safety monitoring of the vehicle. Multiple wiring harnesses enable signal interaction and command transmission between the vehicle controller 1 and on-board sensors, actuators, and other electronic modules. This fault testing equipment includes the fault testing system 2 provided in this application embodiment, which can simulate wiring harness fault scenarios for the vehicle controller 1.

[0033] To enable the fault testing system 2 provided in this application to inject faults into different wiring harness scenarios of the vehicle controller 1, and to achieve comprehensive testing and verification of wiring harness faults of the vehicle controller 1, in one example, such as Figure 2 As shown, the fault testing system 2 includes a fault injection module 21 and a control module 22. The fault injection module 21 includes multiple first test circuits 211, each connected to the vehicle controller 1. The control module 22 is connected to the controlled terminals of the multiple first test circuits 211 and is configured to control the operation of at least one of the multiple first test circuits 211 to switch the fault simulation mode of the fault injection module 21. The fault simulation mode includes at least fault simulation of a single wiring harness and fault simulation of multiple wiring harnesses.

[0034] It should be understood that the multiple first test circuits 211 of this application are connected one-to-one with the wiring harnesses on the vehicle controller 1, ensuring that each wiring harness under test on the vehicle controller 1 can achieve fault detection through an independent circuit, thus guaranteeing the independence of each wiring harness fault simulation circuit. Furthermore, the control logic of the control module 22 for the operation of at least one first test circuit 211 supports independent triggering of a single first test circuit 211 to test a single wiring harness fault simulation, and can also realize the implementation of multiple first test circuits 211 testing multiple wiring harness fault simulations to adapt to different fault testing needs.

[0035] In this example, the fault injection module 21 includes multiple first test circuits 211, each connected to one of the multiple wiring harnesses under test in the vehicle controller 1. Each first test circuit 211 independently corresponds to one wiring harness under test in the vehicle controller 1. At the same time, the control module 22 establishes a control link with the controlled end of all the first test circuits 211 to ensure that the control signal can be accurately transmitted to any one of the first test circuits 211.

[0036] If the fault testing system 2 needs to perform a fault simulation of a single wire harness, the control module 22 can send a control command to the first test circuit 211 corresponding to the wire harness under test, drive the first test circuit 211 to operate independently, so that the wire harness under test works to the fault state through the corresponding first test circuit 211.

[0037] If the fault testing system 2 needs to perform fault simulation for multiple wire harnesses, the control module 22 can send action commands synchronously or according to a preset timing sequence to the first test circuits 211 corresponding to at least two wire harnesses under test, controlling the first test circuits 211 corresponding to these wire harnesses under test to operate collaboratively, thereby realizing fault injection for multiple wire harnesses under test. In the case of fault simulation for multiple wire harnesses, if the control module 22 controls the first test circuits 211 corresponding to two wire harnesses under test to operate, it can be that both wire harnesses under test corresponding to these two first test circuits 211 are tested for open circuit fault simulation, or the two first test circuits 211 are short-circuited to realize short circuit fault detection between the two wire harnesses under test.

[0038] For example, the control module 22 can control the first test circuit 211 of the current action to stop operating, and control the first test circuit 211 corresponding to other wire harnesses under test to operate, so as to flexibly switch between different fault simulation modes of single wire harness fault simulation and multiple wire harness fault simulation, so as to realize the automatic control of multiple fault detection and the continuous realization of comprehensive fault detection, and ensure the fault testing and verification of the vehicle controller 1 under different wire harness quantity scenarios.

[0039] Thus, in the fault testing system 2 provided in this application, the multiple first test circuits 211 of the fault injection module 21 are connected one-to-one with the wiring harness under test of the vehicle controller 1. The control module 22 can independently control the action of a single first test circuit 211 to simulate the fault of the corresponding wiring harness, thereby achieving accurate testing of a single wiring harness fault scenario. The control module 22 can also control at least two first test circuits 211 to act simultaneously to simulate the fault of the corresponding wiring harness, thereby achieving accurate testing of a multi-wiring harness fault scenario. By controlling the action of different numbers of first test circuits 11, the control module 22 can flexibly switch and test single-wiring harness and multi-wiring harness fault scenarios, covering a relatively comprehensive range of wiring harness fault testing scenarios. Secondly, the fault testing system 2 can automatically implement different fault injection operations through the control module 22, eliminating the need for manual operation in related technologies, reducing operation steps. Furthermore, automated testing eliminates the need for manual wiring harness connection, fault state switching, and test data recording, and the testing process is not affected by subjective human factors, resulting in higher testing accuracy and reliability, further supporting the reliability of the vehicle controller 1.

[0040] To enable the fault testing system 2 provided in this application to switch between normal operation testing and fault testing through its circuit structure, and to support efficient simulation of multi-harness faults, in one example, such as Figure 3 As shown, each first test circuit 211 includes a first simulation unit 2111. The controlled terminal of the first simulation unit 2111 serves as the controlled terminal of the first test circuit 211 and is connected to the control module 22. The input terminal of the first simulation unit 2111 is connected to the wiring harness under test of the vehicle controller 1. The output terminal of the first simulation unit 2111 is selectively connected to a normal simulation node a or a fault simulation node b. The fault simulation nodes b of multiple first simulation units 2111 are connected together.

[0041] It should be understood that the normal simulation nodes a connected to the first simulation unit 2111 are not shared. In order to distinguish the normal simulation nodes a connected to different first simulation units 2111, the normal simulation nodes a connected to different first simulation units 2111 are marked as a1, a2, a3, etc. in the figure.

[0042] In this example, the input terminal of the first simulation unit 2111 of each first test circuit 211 is connected one-to-one with a wiring harness under test of the vehicle controller 1. The controlled terminal of the first simulation unit 2111 is connected to the control module 22 to ensure that the first simulation unit 2111 can receive action commands sent by the control module 22. At the same time, the fault simulation nodes b of multiple first simulation units 2111 remain interconnected, enabling fault simulation of multiple wiring harnesses under test.

[0043] If the fault test system 2 needs to simulate the normal working state of a single wiring harness, the control module 22 sends an action command to the first simulation unit 2111 corresponding to the wiring harness under test, driving the output terminal of the first simulation unit 2111 to be connected to the normal simulation node a. At this time, the wiring harness under test simulates the normal connection condition in the real vehicle environment through the normal simulation node a, and the vehicle controller 1 is in normal working state.

[0044] If the fault testing system 2 needs to simulate the fault mode of a single wire harness, the control module 22 sends an action command to the first simulation unit 2111 corresponding to the wire harness under test, driving the output terminal of the first simulation unit 2111 corresponding to the wire harness under test to be connected to the fault simulation node b. Through the preset fault logic corresponding to the fault simulation node b, the wire harness under test is made to enter the fault state, realizing the single wire harness fault injection.

[0045] If it is necessary to simulate fault injection tests of multiple wire harnesses, such as when simulating a short circuit between wire harnesses, the control module 22 sends an action command to the first simulation unit 2111 corresponding to at least two wire harnesses under test, driving the output terminals of the first simulation units 2111 corresponding to these wire harnesses under test to simultaneously conduct with the fault simulation node b. Since all fault simulation nodes b are interconnected, multiple wire harnesses under test form signal interaction through the shared fault simulation node b, thereby realizing the fault simulation of multiple wire harnesses in the fault test system 2.

[0046] During the test, the control module 22 can switch the output terminal of any first simulation unit 2111 to connect with normal simulation node a or fault simulation node b according to the test requirements, so that the fault test system 2 can control the wire harness under test to switch between normal state and fault state, and can also switch between fault simulation of a single wire harness and fault simulation of multiple wire harnesses, so as to continuously realize test verification in different scenarios.

[0047] It should be understood that the first simulation unit 2111 adopts a selective output structure, which can realize two modes: normal simulation and fault simulation. The normal simulation node a can be equivalent to the normal connection environment of the wiring harness under test in a real vehicle environment, while the fault simulation node b is the core node for fault injection. The fault simulation nodes b of multiple first simulation units 2111 are interconnected, which can realize the simulation of open circuit faults of multiple wiring harnesses, as well as the fault detection of multiple wiring harnesses with short circuits between wires. Multiple first simulation units 2111 can connect different wiring harnesses by sharing the fault simulation node b, so as to realize fault simulation testing of complex scenarios.

[0048] Thus, the first simulation unit 2111 is connected one-to-one with the wiring harness under test, and the output of the first simulation unit 2111 can be connected to either a normal simulation node a or a fault simulation node b, enabling flexible switching between normal and fault states for a single wiring harness and ensuring the independence and accuracy of fault simulation for a single wiring harness. Simultaneously, the fault simulation nodes b of multiple first simulation units 2111 can be interconnected, allowing the control module 22 to simulate faults in multiple wiring harnesses, covering line-to-line fault testing scenarios. The control module 22 can automatically and flexibly switch the connection objects of the output of each first fault simulation unit 2111 to achieve flexible switching of fault testing scenarios corresponding to one or more wiring harnesses, improving the flexibility of fault switching and testing in the fault testing system 2 provided in this application. This testing process requires no manual intervention, the testing steps are simpler, and the testing process is unaffected by human factors, resulting in higher testing accuracy and further supporting the effective verification of the wiring harness performance of the vehicle controller 1.

[0049] To enable the fault testing system 2 provided in this application to flexibly switch between simulating the normal state and the fault state of the wire harness under test, in one example, such as Figure 4 As shown, the first simulation unit 2111 includes a first relay LS1, which includes a first coil L1 and a first switch K1. One end of the first coil L1 serves as the controlled end of the first simulation unit 2111 and is connected to the control module 22. The other end of the first coil L1 is connected to the power supply Vdd. The common end of the first switch K1 serves as the input end of the first simulation unit 2111 and is connected to the wiring harness under test of the vehicle controller 1. The first switching end of the first switch K1 is connected to the normal simulation node a, and the second switching end of the first switch K1 is connected to the fault simulation node b.

[0050] In this example, the common terminal of the first switch K1 of each first simulation unit 2111 is connected to a test harness of the vehicle controller 1. One end of the first coil L1 is connected to the control module 22 to receive the action signal output by the control module 22. The other end of the first coil L1 is connected to the power supply Vdd. At the same time, the first switching terminal of the first switch K1 is connected to the normal simulation node a and the second switching terminal is connected to the fault simulation node b. In addition, the fault simulation nodes b of all first simulation units 2111 are interconnected.

[0051] When the control module 22 does not send an action signal to the first coil L1, the first coil L1 is not energized. At this time, the common terminal of the first switch K1 is connected to the first switching terminal of the first switch K1 by default. The wiring harness under test is connected to the normal simulation node a through this path. At this time, the wiring harness under test is in normal working condition. The vehicle controller 1 can simulate the working environment under normal condition through this path.

[0052] If the fault test system 2 needs to switch to the fault simulation mode of a single wire harness, the control module 22 sends an action signal to the first coil L1 corresponding to the wire harness under test. The first coil L1 is energized, driving the common terminal of the first switch K1 to connect with the second switching terminal of the first switch K1. At this time, the wire harness under test is connected to the fault simulation node b through the path of the first switch K1, and enters the fault simulation state through the preset logic of the fault simulation node b, realizing the fault injection test of a single wire harness.

[0053] If the fault testing system 2 needs to simulate the faults of multiple wire harnesses, the control module 22 synchronously sends action signals to the first coil L1 corresponding to at least two wire harnesses under test, so that the common terminal of these first switches K1 are switched to the second switching terminal of the first switch K1. Since all fault simulation nodes b are interconnected, multiple wire harnesses under test form a connection path through the fault simulation nodes b as a common node, thereby realizing the fault simulation of multiple wire harnesses.

[0054] For example, if the fault simulation node b is in an open circuit state, multiple wire harnesses under test are connected through the fault simulation node b, and the fault test system 2 provided in this application can simulate short circuit faults of multiple wire harnesses under test.

[0055] It should be understood that if the first relay LS1 corresponding to two wire harnesses under test is activated, the fault test system 2 can perform short-circuit fault testing on the two wire harnesses; if three wire harnesses under test are connected at the same time and the corresponding first relay LS1 is activated, the short-circuit fault testing of the connection of the three wire harnesses can be performed. Similarly, the short-circuit fault testing between other different wire harnesses can also be achieved through this principle, which will not be elaborated further.

[0056] During the test, the control module 22 can flexibly switch the connection path of the first switch K1 by controlling the on / off state of the first coil L1. It can switch between the normal state simulation and the fault state simulation of a single wire harness, as well as between a single wire harness fault and multiple wire harness faults, in order to complete the stability test verification of different scenarios.

[0057] Optionally, the first switch K1 can be a single-pole double-throw switch, or it can include two independent switches. The controlled terminals of the two independent switches are connected to the control module 22. It is worth noting that when the first switch K1 consists of two independent switches, the on / off states of the two switches are always opposite; that is, when one is on, the other is off, to achieve different output paths. The first switch K1 provided in this application can be any of the aforementioned devices or other devices or circuits capable of selecting different output paths. This application does not impose specific limitations on this.

[0058] Thus, the first simulation unit 2111 uses the first relay LS1, which drives the first switch K1 through the first coil L1, achieving accurate switching between the normal state simulation and the fault state simulation of the harness under test, ensuring the reliability of the single harness fault simulation test. Furthermore, the relay's hardware on / off logic has strong anti-interference capabilities, avoiding environmental interference and better reflecting the physical connection characteristics of harnesses in the actual vehicle environment, improving the effectiveness and accuracy of fault simulation switching and testing based on this relay. When multiple harnesses' corresponding fault simulation nodes b are interconnected, combined with the relay's control, multiple harness faults can be simulated. Simultaneously, the flexible control of the first coil L1's on / off action by the control module 22 enhances the testing flexibility and further improves the stability and comprehensiveness of the vehicle controller 1's harness fault testing.

[0059] To enable the fault testing system 2 provided in this application to simulate ground short-circuit faults in the harness under test and improve the comprehensiveness of fault testing, in one example, such as Figure 5As shown, the fault testing system 2 also includes a second test circuit 212. The controlled terminal of the second test circuit 212 is connected to the control module 22, the input terminal of the second test circuit 212 is connected to the fault simulation node b, and the output terminal of the second test circuit 212 is selectively grounded or open-circuited. The fault simulation mode also includes a short-circuit fault simulation to ground.

[0060] In this example, the multiple first test circuits 211 of the fault injection module 21 are connected to the wiring harness under test of the vehicle controller 1. After the fault simulation node b of each first test circuit 211 is interconnected, it is connected to the input terminal of the second test circuit 212. The controlled terminal of the second test circuit 212 is connected to the control module 22. The output terminal of the second test circuit 212 can be selectively grounded or open-circuited.

[0061] When the fault test system 2 does not need to simulate a short circuit to ground fault, the control module 22 controls the output terminal of the second test circuit 212 to remain open. At this time, the fault simulation node b is used to simulate faults of a single wire harness or multiple wire harnesses. The fault test system 2 can complete the test of the corresponding fault scenario according to the original test method.

[0062] If the fault testing system 2 needs to simulate a single wire harness short-circuit fault to ground, the control module 22 sends an action command to the first test circuit 211 corresponding to the wire harness under test, so that the output terminal of the first test circuit 211 corresponding to the wire harness under test is connected to the fault simulation node b. The control module 22 controls the second test circuit 212 to operate, driving the output terminal of the second test circuit 212 to ground. At this time, the wire harness under test forms a loop to ground through the fault simulation node b and the second test circuit 212, and enters the short-circuit fault to ground test mode, realizing the injection test of a single wire harness short-circuit fault to ground.

[0063] If the fault test system 2 needs to simulate a fault test in which multiple wire harnesses are simultaneously short-circuited to ground, the control module 22 can send instructions to the first test circuit 211 corresponding to at least two wire harnesses under test, so that the output terminals of the first test circuit 211 corresponding to the wire harnesses under test are switched to the fault simulation node b, and then control the output terminal of the second test circuit 212 to be grounded. Multiple wire harnesses under test are connected to the second test circuit 212 through the shared fault simulation node b, and synchronously enter the ground short-circuit fault simulation mode to realize the simulation of multiple wire harnesses short-circuit faults to ground.

[0064] Thus, the fault testing system 2 provided in this application is connected to the fault simulation node b through the second test circuit 212, enabling the fault testing system 2 to simulate ground short-circuit faults, enriching the test types of wiring harness faults in the vehicle controller 1. Secondly, by sharing the fault simulation node b, the control module 22 can control the operation of multiple first test circuits 211 to simultaneously connect multiple wiring harnesses to the fault simulation node b, simulating ground short-circuit faults simultaneously through the second test circuit 212. Furthermore, the control module 22 can flexibly switch the output state of the second test circuit 212 to achieve rapid switching between ground short-circuit faults and other fault modes in the fault testing circuit 2, making fault testing more flexible. This process requires no manual operation; the control module 22 can automatically control the operation of the first and second test circuits, simplifying the testing process and ensuring that the test results are not affected by subjective factors, resulting in higher test accuracy and further improving the completeness of wiring harness fault testing for the vehicle controller 1.

[0065] In order to enable the fault testing system 2 provided in this application to switch between ground short-circuit fault and open-circuit states, in one example, such as Figure 6 As shown, the second test circuit 212 includes a second relay LS2, which includes a second coil L2 and a second switch K2. One end of the second coil L2 serves as the controlled terminal of the second test circuit 212 and is connected to the control module 22. The other end of the second coil L2 is connected to the power supply Vdd. The common terminal of the second switch K2 serves as the input terminal of the second test circuit 212 and is connected to the fault simulation node b. The first switching terminal of the second switch K2 is grounded, and the second switching terminal of the second switch K2 is configured to be in an open-circuit state.

[0066] In this example, the common terminal of the second switch K2 in the second test circuit 212 is connected to the fault simulation node b, one end of the second coil L2 is connected to the control module 22, the other end of the second coil L2 is connected to the power supply Vdd, the first switching terminal of the second switch K2 is grounded, and the second switching terminal of the second switch K2 remains open.

[0067] When the fault test system 2 does not need to simulate a short circuit to ground fault, the control module 22 does not send an action signal to the second coil L2, the second coil L2 remains de-energized, and the common terminal of the second switch K2 is connected to the second switching terminal of the second switch K2 by default. At this time, the second test circuit 212 is in an open circuit state.

[0068] When the fault testing system 2 simulates an open-circuit fault in a single wire harness, the control module 22 keeps the second relay LS2 in the second test circuit 212 inactive, i.e., maintains the open-circuit state of the second test circuit 212. Simultaneously, it sends an action signal to the first test circuit 211 corresponding to the wire harness under test, driving the first relay LS1 in the first test circuit 211 to activate, thus connecting the output of the first simulation unit 2111 to the fault simulation node b. Since the second test circuit 212 connected to the fault simulation node b is in an open-circuit state, the wire harness under test is connected to the open-circuit second test circuit 212 through the fault simulation node b, thereby simulating the open-circuit fault of the single wire harness under test.

[0069] If the fault test system 2 needs to simulate a short circuit to ground, the control module 22 sends a control signal to the second coil L2, energizing the second coil L2 and driving the common terminal of the second switch K2 to conduct with the first switching terminal of the second switch K2. At this time, the fault simulation node b forms a path to ground through the second test circuit 212. If it is necessary to trigger a short circuit to ground of a single wire harness, the control module 22 synchronously sends a command to the first test circuit 211 corresponding to the wire harness under test, causing the output terminal of the first test circuit 211 corresponding to the wire harness under test to switch to the fault simulation node b. The wire harness under test can then form a ground loop through the fault simulation node b and the second test circuit 212 to realize the short circuit to ground fault test.

[0070] If the fault test system 2 needs to simulate multiple wire harnesses being short-circuited to ground simultaneously, the control module 22 sends instructions to the first test circuit 211 corresponding to at least two wire harnesses under test, so that the output terminals of the corresponding first test circuit 211 are switched to the fault simulation node b. At the same time, the second switch K2 of the second test circuit 212 is switched to the ground terminal, and multiple wire harnesses under test can enter the short-circuit fault state to ground synchronously through the shared fault simulation node b.

[0071] Thus, by controlling the operation of the second coil L2 of the second test circuit 212, the control module 22 grounds or opens the second switch K2, enabling flexible switching between short-circuit to ground and open-circuit fault tests of the vehicle controller 1 wiring harness, ensuring the reliability of the short-circuit to ground fault simulation in the fault test system 2. Furthermore, by controlling the open-circuit state of the second test circuit 212 and the operation of the first test circuit 211, the control module 22 can also perform open-circuit fault tests on a single wiring harness, allowing the fault test system 2 to flexibly switch fault injection modes and improving the effectiveness of wiring harness fault testing for the vehicle controller 1.

[0072] In order for the fault testing system 2 provided in this application to simulate a power supply short-circuit fault in the harness under test, in one example, such as Figure 7As shown, the fault testing system 2 also includes a third test circuit 213. The controlled terminal of the third test circuit 213 is connected to the control module 22, the input terminal of the third test circuit 213 is connected to the fault simulation node b, and the output terminal of the third test circuit 213 is selectively connected to the power supply simulation node c or an open circuit. The fault simulation mode also includes simulation of a power supply short-circuit fault.

[0073] In this example, the input terminals of the second test circuit 212 and the third test circuit 213 are simultaneously connected to the fault simulation node b. The controlled terminal of the third test circuit 213 is connected to the control module 22. The output terminal of the third test circuit 213 corresponds to the power supply simulation node c and the open circuit state, respectively.

[0074] When the fault test system 2 does not need to simulate a power supply short circuit fault, the control module 22 controls the output terminal of the third test circuit 213 to remain in an open circuit state. At this time, the fault simulation node b can be used normally for simulating fault scenarios such as open circuit, multi-wire harness short circuit fault detection, and short circuit to ground.

[0075] If the fault testing system 2 needs to perform a fault test for a single wire harness to a power supply short circuit, the control module 22 sends an action signal to the third test circuit 213, driving the output of the third test circuit 213 to connect with the power supply simulation node c. The control module 22 also sends an action command to the first test circuit 211 corresponding to the wire harness under test, causing the output of the first test circuit 211 corresponding to the wire harness under test to switch to the fault simulation node b. At this time, the wire harness under test is connected to the third test circuit 213 through the fault simulation node b and connected to the power supply simulation node c, thus entering the detection state for the wire harness under test to detect a power supply short circuit fault.

[0076] If the fault testing system 2 needs to perform simultaneous power supply short-circuit fault testing on multiple wire harnesses, the control module 22 can control the output terminal of the third test circuit 213 to connect to the power supply simulation node c, and control the operation of the first test circuit 211 corresponding to at least two wire harnesses under test, so that the output terminals of the corresponding first test circuit 211 are all connected to the fault simulation node b. Multiple wire harnesses under test, by sharing the fault simulation node b, are synchronously connected to the power supply simulation node c, realizing the simultaneous power supply short-circuit fault simulation of multiple wire harnesses.

[0077] Thus, by setting up a third test circuit 213 and connecting it to the fault simulation node b, the fault test system 2 can simulate power short-circuit faults. Each test circuit shares the fault simulation node b, allowing the control module 22 to coordinate the operation of multiple first test circuits 211, simulating power short-circuit faults in multiple wiring harnesses. By switching the output state of the third test circuit 213, the control module 2 can flexibly switch the fault injection mode of the wiring harness, simulating power short-circuit faults or switching to other fault modes. This makes the fault type coverage of the fault test system 2 more comprehensive. Furthermore, this flexible switching of fault injection modes requires no manual operation, reducing test steps, and the test results are not affected by subjective factors, resulting in higher accuracy and further improving the comprehensiveness and reliability of the wiring harness fault testing of the vehicle controller 1.

[0078] Optionally, the second switch K2 can be a single-pole double-throw switch, or it can include two independent switches. The controlled terminals of the two independent switches are connected to the control module 22. It is worth noting that when the second switch K2 consists of two independent switches, the on / off states of the two switches are always opposite; that is, when one is on, the other is off, to achieve different output paths. The second switch K2 provided in this application can be selected from the above-mentioned devices or other devices or circuits capable of selecting different output paths. This application does not impose specific limitations on this.

[0079] In order to enable the fault testing system 2 provided in this application to switch control for power short-circuit faults, in one example, such as Figure 8 As shown, the third test circuit 213 includes a third relay LS3, which includes a third coil L3 and a third switch K3. One end of the third coil L3 serves as the controlled terminal of the third test circuit 213 and is connected to the control module 22. The other end of the third coil L3 is connected to the power supply Vdd. The common terminal of the third switch K3 serves as the input terminal of the third test circuit 213 and is connected to the fault simulation node b. The first switching terminal of the third switch K3 is connected to the power supply simulation node c, and the second switching terminal of the third switch K3 is configured to be in an open-circuit state.

[0080] In this example, the common terminal of the third switch K3 of the third test circuit 213 is connected to the fault simulation node b, one end of the third coil L3 is connected to the control module 22, the other end of the third coil L3 is connected to the power supply Vdd, the first switching terminal of the third switch K3 is connected to the power supply simulation node c, and the second switching terminal of the third switch K3 remains open.

[0081] When the fault test system 2 does not need to simulate a power supply short circuit fault, the control module 22 controls the third coil L3 to not operate, the third coil L3 remains de-energized, and the common terminal of the third switch K3 is connected to the second switching terminal of the third switch K3 by default. At this time, the third test circuit 213 is in an open circuit state, and the fault simulation node b can realize the test simulation of faults such as open circuit, multiple wire harness short circuit, and short circuit to ground.

[0082] If the fault testing system 2 needs to perform a short-circuit fault test on a single wire harness to the power supply, the control module 22 sends an action signal to the third coil L3. The third coil L3 is energized, driving the common terminal of the third switch K3 to connect with the first switching terminal of the third switch K3, so that the fault simulation node b is connected to the power supply simulation node c through the third switch K3. At the same time, the control module 22 sends an action command to the first test circuit 211 corresponding to the wire harness under test, driving the first switch K1 of the first test circuit 211 corresponding to the wire harness under test to switch to the fault simulation node b. At this time, the wire harness under test is connected to the power supply simulation node c through the fault simulation node b and the third test circuit 213, realizing the short-circuit fault test of the wire harness to the power supply.

[0083] If the fault testing system 2 needs to simulate power short circuit faults for multiple wire harnesses simultaneously, the control module 22 controls the third switch K3 of the third test circuit 213 to open the path connected to the power simulation node c. The control module 22 controls the first test circuit 211 corresponding to at least two wire harnesses under test to operate, so that the output terminals of the first test circuit 211 corresponding to the wire harnesses under test are switched to the fault simulation node b. Multiple wire harnesses under test are synchronously connected to the power simulation node c through the shared fault simulation node b, so as to realize the simultaneous simulation of power short circuit faults for multiple wire harnesses.

[0084] Optionally, the third switch K3 can be a single-pole double-throw switch, or it can include two independent switches. The controlled terminals of the two independent switches are connected to the control module 22. It is worth noting that when the third switch K3 consists of two independent switches, the on / off states of the two switches are always opposite; that is, when one is on, the other is off, to achieve different output paths. The third switch K3 provided in this application can be any of the aforementioned devices or other devices or circuits capable of selecting different output paths. This application does not impose specific limitations on this.

[0085] Thus, control module 22 can energize the third relay LS3 in the third test circuit 213, causing the third coil L3 to drive the third switch K3 to select the power supply. This enables the fault test system 2 to simulate power supply short-circuit faults. The use of relay hardware switching also ensures the reliability of the wiring harness's simulation of power supply short-circuit faults. Control module 22 can control the operation of the first test circuit 211 corresponding to multiple wiring harnesses under test. Combined with the shared design of fault simulation node b, it can realize the simultaneous simulation of power supply short-circuit faults for multiple wiring harnesses, further improving the fault test types of fault test system 2 and effectively supporting the comprehensiveness of wiring harness fault testing of vehicle controller 1.

[0086] To enable the fault testing system 2 provided in this application to simultaneously simulate single wire harness faults and multiple wire harness faults, a switching control between ground short circuit and power supply short circuit faults is combined. In one example, such as... Figure 9 As shown, the fault testing system 21 also includes a fourth test circuit 214 and a fifth test circuit 215. The fourth test circuit 214 includes a fourth relay LS4, which includes a third coil L4 and a fourth switch K4. One end of the third coil L4 is connected to the control module 22. The first common terminal of the fourth switch K4 is connected to the fault simulation node b, and the second common terminal of the fourth switch K4 is connected to the power supply Vdd. The first switching terminal of the fourth switch K4 is configured as an open circuit, the second switching terminal of the fourth switch K4 is grounded, and the third switching terminal of the fourth switch K4 is configured as an open circuit. The fifth test circuit 215 includes a fifth relay LS5, which includes a fifth coil L5 and a fifth switch K5. One end of the fifth coil L5 is connected to the control module 22, and the other end of the fifth coil L5 is connected to the fourth switching terminal of the fourth switch K4. The first common terminal of the fifth switch K5 is connected to the first common terminal of the fourth switch K4 and the fault simulation node b. The second common terminal of the fifth switch K5 is connected to the power supply Vdd. The first switching terminal of the fifth switch K5 is configured as an open circuit. The second switching terminal of the fifth switch K5 is connected to the power supply simulation node c. The third switching terminal of the fifth switch K5 is configured as an open circuit. The fourth switching terminal of the fifth switch K5 is connected to the other end of the third coil L4.

[0087] It is worth noting that the fault simulation mode also includes simulations of short circuits to ground and short circuits to power supply. During the short circuit to ground simulation, the first common terminal of the fourth switch K4 is connected to the second switching terminal of the fourth switch K4, and the second common terminal of the fourth switch K4 is connected to the third switching terminal of the fourth switch K4. During the short circuit to power supply simulation, the first common terminal of the fifth switch K5 is connected to the second switching terminal of the fifth switch K5, and the second common terminal of the fifth switch K5 is connected to the third switching terminal of the fifth switch K5.

[0088] In this example, the first common terminal of the fourth switch K4 in the fourth test circuit 214 and the first common terminal of the fifth switch K5 in the fifth test circuit 215 are both connected to the fault simulation node b. One end of the third coil L4 and the fifth coil L5 are respectively connected to the control module 22. The second common terminals of the fourth switch K4 and the fifth switch K5 are both connected to the power supply Vdd. At the same time, the other end of the fifth coil L5 is connected to the fourth switching terminal of the fourth switch K4, and the fourth switching terminal of the fifth switch K5 is connected to the other end of the third coil L4.

[0089] It should be understood that the fourth switching terminal of the fourth switch K4 is connected to the other end of the fifth coil L5, and the fourth switching terminal of the fifth switch K5 is connected to the other end of the third coil L4. This cross-connection design forms an interlock. When the third coil L4 is energized, driving the fourth switch K4 to operate, the fourth switching terminal of the fourth switch K4 will disconnect the path to the fifth coil L5, preventing the fifth coil L5 from being energized. Similarly, when the fifth coil L5 is energized, driving the fifth switch K5 to operate, the fourth switching terminal of the fifth switch K5 will disconnect the path to the third coil L4, preventing the third coil L4 from being energized. This avoids the simultaneous operation of the fourth test circuit 214 and the fifth test circuit 215, preventing the simultaneous triggering of short-circuit to ground and short-circuit to power supply fault modes, thus providing interlock protection for the circuit power supply and ensuring the safety of the fault test system 2 during the testing process.

[0090] When the fault testing system 2 does not need to simulate short circuits to ground or power supply, the control module 22 de-energizes the third coil L4 and the fifth coil L5. The first common terminal of the fourth switch K4 is connected to the first switching terminal of the fourth switch K4 by default, and the fourth switch K4 remains open. The first common terminal of the fifth switch K5 is also connected to the first switching terminal of the fifth switch K5 by default, and the fifth switch K5 remains open. At this time, fault simulation node b can be used to simulate faults such as short circuits and open circuits in a single wire harness, as well as short circuits in multiple wire harnesses.

[0091] If the fault testing system 2 needs to simulate a short circuit to ground, the control module 22 sends an action signal to the third coil L4, energizing the third coil L4 and driving the fourth switch K4 to operate. This connects the first common terminal of the fourth switch K4 to the second switching terminal, grounding the first common terminal. Simultaneously, the second common terminal of the fourth switch K4 connects to the third switching terminal, opening the second common terminal. At this time, the fault simulation node b is grounded through the fourth switch K4. If the control module 22 synchronously sends an action command to the first test circuit 211 corresponding to the wire harness under test, switching its switch to the fault simulation node b, the short circuit to ground fault test of the wire harness under test can be achieved. If the first test circuits 211 corresponding to multiple wire harnesses are controlled to switch to the fault simulation node b, the simultaneous simulation of short circuit to ground faults of multiple wire harnesses can be achieved.

[0092] If the fault testing system 2 needs to simulate a power supply short circuit fault, the control module 22 sends an action signal to the fifth coil L5, energizing the fifth coil L5 and driving the fifth switch K5 to operate. This connects the first common terminal of the fifth switch K5 to the second switching terminal of the fifth switch K5, at which point the first common terminal of the fifth switch K5 is connected to the power supply simulation node c. Simultaneously, the second common terminal of the fifth switch K5 is connected to the third switching terminal of the fifth switch K5, and the second common terminal of the fifth switch K5 is open. At this time, the fault simulation node b is connected to the power supply simulation node c through the fifth switch K5. If the control module 22 synchronously sends an action command to the first test circuit 211 corresponding to the wire harness under test, causing the first switch K1 in the corresponding first test circuit 211 to switch its first common terminal to the fault simulation node b, the power supply short circuit fault test of the wire harness under test can be realized. If the first test circuits 211 corresponding to multiple wire harnesses are controlled to switch to the fault simulation node b, the fault simulation of multiple wire harnesses simultaneously short-circuiting to the power supply can be realized.

[0093] Optionally, the fourth switch K4 and the fifth switch K5 can be double-pole double-throw switches, or each of them can include two independent sets of single-pole double-throw switches, with the controlled terminals of both sets of independent single-pole double-throw switches connected to the control module 22. Specifically, the common terminal of one single-pole double-throw switch corresponds to the first common terminal of the fourth switch K4 / fifth switch K5, and the first and second switching terminals of this single-pole double-throw switch correspond to the first and second switching terminals of the fourth switch K4 / fifth switch K5, respectively. The common terminal of the other single-pole double-throw switch corresponds to the second common terminal of the fourth switch K4 / fifth switch K5, and the first and second switching terminals of this single-pole double-throw switch correspond to the third and fourth switching terminals of the fourth switch K4 / fifth switch K5, respectively.

[0094] It is worth noting that when the fourth switch K4 and the fifth switch K5 are two independent sets of single-pole double-throw switches, the on / off states of the two sets of switches are always synchronously linked. That is, the common terminal of the two sets of single-pole double-throw switches is simultaneously connected to their respective first switching terminals or simultaneously connected to their respective second switching terminals, so as to realize the synchronous switching of the two signals and thus form different output paths. The fourth switch K4 and the fifth switch K5 provided in this application can be selected from the above-mentioned devices or other devices or circuits that can realize the synchronous selection of different output paths for two signals. This application does not impose specific restrictions on this.

[0095] Thus, the fourth test circuit 214 and the fifth test circuit 215 are cross-connected through the fourth switch K4 and the fifth switch K5, completely avoiding the simultaneous triggering of both ground short circuit and power short circuit fault modes at the hardware level. This effectively prevents the circuit from experiencing overcurrent or burnout due to the superposition of the two short circuit faults, ensuring the electrical safety and equipment stability of the fault simulation test process. In addition, for the fault testing requirements of a single wire harness, the control module 22 can precisely control the operation of the first test circuit 211 corresponding to the wire harness under test, connecting the first test circuit 211 to the fault simulation node b, and simultaneously driving the fourth relay LS4 or the fifth relay LS5 to operate. Through the fourth test circuit 214 or the fifth test circuit 215, the ground short circuit fault simulation or the power short circuit fault simulation of a single wire harness can be realized respectively. To address the fault testing requirements of multiple wiring harnesses, the control module 22 can control the connection of the first test circuit 211 corresponding to multiple wiring harnesses under test to the fault simulation node b, and then control the operation of the fourth relay LS4 or the fifth relay LS5, so that multiple wiring harnesses can simultaneously simulate short circuits to ground or to the power supply through the shared fault simulation node b. By automatically controlling the operation of the fourth test circuit 214 and the fifth test circuit 215 through the control module 22, not only is the accuracy of fault simulation for different numbers of wiring harnesses ensured, but manual operation is also eliminated, simplifying the triggering logic of complex fault scenarios. This improves operational convenience and further enhances the testing reliability of the fault testing system 2, thereby increasing the efficiency of wiring harness fault testing for the vehicle controller 1.

[0096] To ensure stable connectivity between the functional modules of the fault testing system 2 provided in this application, in one example, such as Figure 10 As shown, the fault testing system 2 also includes a first connection module 23 and a second connection module 24. The first end of the first connection module 23 is connected to the control module 22, and the second end of the first connection module 23 is connected to the fault injection module 21. The first end of the second connection module 24 is connected to the fault injection module 21, and the second end of the second connection module 24 is connected to the vehicle controller 1.

[0097] In this example, the core function of the first connection module 23 is to establish a signal path between the control module 22 and the fault injection module 21, enabling the control module 22 to transmit control commands to the fault injection module 21 and ensuring the accurate triggering of fault simulation actions. At the same time, the connection method of the first connection module 23 also facilitates the rapid disassembly, maintenance, or replacement of the fault injection module 21 and the control module 22.

[0098] The core function of the second connection module 24 is to establish a physical connection between the fault injection module 21 and the vehicle controller 1, enabling the fault injection module 21 to connect to the wiring harness under test of the vehicle controller 1 and complete the injection of fault states and signal interaction. The second connection module 24 enables the fault test system 2 to adapt to vehicle controllers 1 with different interface specifications, improving the system's compatibility.

[0099] Thus, the first connection module 23 establishes a stable signal path between the control module 22 and the fault injection module 21, ensuring accurate transmission of control commands. Simultaneously, the modular connection enhances the convenience of module disassembly, assembly, and maintenance. The second connection module 24 establishes a physical connection between the fault injection module 21 and the vehicle controller 1, ensuring signal interaction for fault injection and enhancing the compatibility of the fault testing system 2 with vehicle controllers 1 of different interface specifications. This further improves the practicality and adaptability of the fault testing system 2, providing reliable connection support for the stable conduct of fault simulation tests.

[0100] In one possible implementation, such as Figure 10 As shown, the control module 22 may include a host computer 222 and a HIL cabinet 221. The HIL cabinet 221 is a hardware-in-the-loop simulation test cabinet. HIL stands for Hardware-in-the-Loop, which is the core component of the hardware-in-the-loop simulation system.

[0101] In this example, the host computer 222 acts as an operating terminal, enabling the configuration of fault test scenarios, the issuance of test commands, and the monitoring of test data. The HIL cabinet 221, as the core of the hardware-in-the-loop simulation, is responsible for converting the host computer's commands into hardware control signals and transmitting them to the fault injection module 21 through the first connection module 23. Simultaneously, it can collect the interaction data between the fault injection module 21 and the vehicle controller 1 and feed the data back to the host computer 222 for analysis.

[0102] The following is an exemplary description of the overall testing process of the fault testing system 2 provided in this application: Step 1, Rack Hardware Environment Setup: Complete the setup of the rack hardware environment required for fault testing, including the deployment and connection of hardware such as fault injection module 21 and control module 22.

[0103] The fault injection module 21, control module 22 and other hardware are installed according to the design, and the signal path between each piece of hardware is realized through the first and second connection modules to ensure that the hardware can communicate normally.

[0104] Step 2, Vehicle Model Building: Build a vehicle model corresponding to the object under test to provide a virtual vehicle operating environment for hardware-in-the-loop simulation.

[0105] A virtual vehicle model matching the vehicle controller 1 under test is constructed using simulation tools to simulate the power, circuit and other operating logic of the real vehicle, allowing hardware testing to combine the virtual environment to restore the real working conditions.

[0106] Step 3, host computer interface design: Design the interface of the host computer 222 to realize a visual operation entry for functions such as test command issuance and data monitoring.

[0107] The design of the host computer 222's operating interface will present functions such as sending fault test action commands and viewing test data in a visual form, reducing the technical threshold of test operations and improving operational efficiency.

[0108] Step 4, Environment Debugging: Perform joint environment debugging on the established hardware environment, vehicle model and host computer interface to ensure that all parts run in tandem.

[0109] Collaborative testing was conducted on the hardware, virtual model, and host computer 22 to verify whether control commands could be sent from the interface to the hardware and whether hardware signals could be synchronized to the model and the interface, thus eliminating communication or adaptation issues in each stage.

[0110] Step 5, Test Case Writing: Write test cases that cover various failure scenarios and clarify the test content and judgment criteria under different failure modes.

[0111] For each type of fault, such as a single wire harness or multiple wire harnesses, test procedures and judgment criteria are formulated to ensure that the test process has clear execution and evaluation standards.

[0112] Step 6, Test Sequence Development: Develop automated test sequences based on test cases to automate the fault testing process.

[0113] Transforming test case steps into automated scripts allows the system to automatically trigger faults and collect data according to preset logic, replacing repetitive manual operations and improving testing efficiency and consistency.

[0114] Step 7, Test Execution: Perform fault tests according to the test sequence to complete signal interaction and data acquisition under various fault scenarios.

[0115] The automated test sequence is run, and the fault test system 2 automatically triggers various faults. At the same time, it collects the response data and hardware status signals of the vehicle controller 1 to provide raw test data for subsequent analysis.

[0116] Step 8, Test Report Generation: Generate a test report based on the data collected during the test execution process, recording the test results and analysis conclusions.

[0117] The above testing process may also include additional testing steps according to actual testing needs, and this application does not impose specific restrictions on this.

[0118] This application embodiment also provides a fault testing device, which includes the fault testing system 2 described in any of the above optional methods. The fault testing system 2 is used to test the performance of the vehicle controller 1, and thus has all the effects that the fault testing system 2 can achieve. Further details will not be provided here.

[0119] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as the combination of these technical features does not contradict each other, it should be considered to be within the scope of this specification.

[0120] The above embodiments merely illustrate several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A fault testing system applied to a vehicle, said vehicle including a vehicle controller, characterized in that, The fault testing system includes: A fault injection module, comprising multiple first test circuits, each of which is connected to the vehicle controller; and... A control module is connected to the controlled terminals of a plurality of first test circuits, and the control module is configured to control the operation of at least one of the plurality of first test circuits to switch the fault simulation mode of the fault injection module. The fault simulation mode includes at least fault simulation of a single wire harness and fault simulation of multiple wire harnesses.

2. The fault testing system according to claim 1, characterized in that, Each of the first test circuits includes: The first simulation unit has its controlled terminal serving as the controlled terminal of the first test circuit and connected to the control module. The input terminal of the first simulation unit is connected to the wiring harness under test of the vehicle controller. The output terminal of the first simulation unit is selectively connected to a normal simulation node or a fault simulation node. The fault simulation nodes of multiple first simulation units are connected.

3. The fault testing system according to claim 2, characterized in that, The first analog unit includes a first relay, and the first relay includes a first coil and a first switch; One end of the first coil serves as the controlled end of the first simulation unit and is connected to the control module. The other end of the first coil is connected to the power supply. The common end of the first switch serves as the input end of the first simulation unit and is connected to the wiring harness under test of the vehicle controller. The first switching end of the first switch is connected to the normal simulation node, and the second switching end of the first switch is connected to the fault simulation node.

4. The fault testing system according to claim 2, characterized in that, The fault testing system also includes: The second test circuit has its controlled terminal connected to the control module, its input terminal connected to the fault simulation node, and its output terminal selectively grounded or open-circuited. The fault simulation mode also includes a ground short-circuit fault simulation.

5. The fault testing system according to claim 4, characterized in that, The second test circuit includes a second relay, which includes a second coil and a second switch; One end of the second coil serves as the controlled end of the second test circuit and is connected to the control module. The other end of the second coil is connected to the power supply. The common end of the second switch serves as the input end of the second test circuit and is connected to the fault simulation node. The first switching end of the second switch is grounded, and the second switching end of the second switch is configured to be in an open circuit state.

6. The fault testing system according to claim 5, characterized in that, The fault testing system also includes: The third test circuit has its controlled terminal connected to the control module, its input terminal connected to the fault simulation node, and its output terminal selectively connected to the power supply simulation node or an open circuit. The fault simulation mode also includes simulation of power supply short-circuit faults.

7. The fault testing system according to claim 6, characterized in that, The third test circuit includes a third relay, which includes a third coil and a third switch; One end of the third coil serves as the controlled end of the third test circuit and is connected to the control module. The other end of the third coil is connected to the power supply. The common end of the third switch serves as the input end of the third test circuit and is connected to the fault simulation node. The first switching end of the third switch is connected to the power simulation node, and the second switching end of the third switch is configured to be in an open circuit state.

8. The fault testing system according to claim 2, characterized in that, The fault testing system also includes: A fourth test circuit, comprising a fourth relay, the fourth relay including a fourth coil and a fourth switch, one end of the fourth coil connected to the control module, a first common terminal of the fourth switch connected to the fault simulation node, a second common terminal of the fourth switch connected to a power supply, a first switching terminal of the fourth switch configured as an open circuit, a second switching terminal of the fourth switch grounded, and a third switching terminal of the fourth switch configured as an open circuit; and, The fifth test circuit includes a fifth relay, which includes a fifth coil and a fifth switch. One end of the fifth coil is connected to the control module, and the other end of the fifth coil is connected to the fourth switching terminal of the fourth switch. The first common terminal of the fifth switch is connected to the first common terminal of the fourth switch and the fault simulation node. The second common terminal of the fifth switch is connected to the power supply. The first switching terminal of the fifth switch is configured as an open circuit. The second switching terminal of the fifth switch is connected to the power supply simulation node. The third switching terminal of the fifth switch is configured as an open circuit. The fourth switching terminal of the fifth switch is connected to the other end of the fourth coil.

9. The fault testing system according to any one of claims 1 to 8, characterized in that, The fault testing system also includes: A first connection module, wherein a first end of the first connection module is connected to the control module, and a second end of the first connection module is connected to the fault injection module; and... The second connection module has a first end connected to the fault injection module and a second end connected to the vehicle controller.

10. A fault testing device, characterized in that, The device includes: The fault testing system as described in any one of claims 1 to 9.

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