Vehicle ECU Fault Injection Using On-Chip Debugging
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Solution Overview
Problem
Conventional fault injection tests for vehicle control software are inefficient due to manual intervention, high costs, and inaccuracies caused by communication delays between debuggers and electronic control units (ECUs), which hinder the ability to accurately inject faults and generate automated test reports.
Innovation Solution
A fault injection test method and apparatus that utilizes an on-chip debugging system (OCDS) within the vehicle controller's CPU to set and execute fault injection conditions, including fault modes like task stop, task miss, and variable manipulation, allowing for precise fault injection without interrupting the ECU's execution flow and independent of debugger communication delays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual fault injection testing is performed using a debugger, then the testing process can be controlled and monitored, but the testing efficiency is low and the cost is high due to manual intervention
Solution Approach 1:
The system enables automated fault injection testing where the test apparatus automatically injects faults into the ECU, monitors the responses, and generates test reports without requiring manual debugger intervention. The ECU's own error recovery mechanisms are tested through automated fault injection, making the system self-testing capable.
Solution Approach 2:
A fault injection test apparatus is introduced as an intermediary between the tester and the ECU. This apparatus automatically manages fault injection, monitoring, and report generation, eliminating the need for manual debugger operations while maintaining comprehensive test control.
2Measurement precision
If fault injection is performed through a debugger with communication between host and ECU, then fault injection can be attempted, but inaccuracies occur due to communication delays affecting the timing of fault injection
Solution Approach 1:
The fault injection functionality is extracted from the external debugger-host communication system and embedded directly into the ECU through a trap function. This eliminates the communication delay between host and ECU by performing fault injection locally within the ECU's own processing architecture.
Solution Approach 2:
The trap function is pre-configured within the ECU with fault injection conditions and parameters. When specific conditions are met during ECU operation, the pre-configured trap function automatically executes the fault injection without requiring real-time communication with the host system, ensuring precise timing.
3Loss of time
If automated fault injection testing is implemented, then testing efficiency improves and time is reduced, but the system complexity increases due to the need for automated monitoring and report generation
Solution Approach 1:
The fault injection test apparatus combines multiple functions into a single integrated system: fault injection capability, real-time monitoring of ECU responses, error detection, and automated test report generation. This consolidation reduces overall system complexity compared to having separate systems for each function.
Solution Approach 2:
The fault injection test apparatus is designed as a multi-functional device that can perform fault injection, monitor ECU responses, detect errors, and generate reports across different fault scenarios. This universal design reduces the need for multiple specialized devices, simplifying the overall testing infrastructure.
Data Source
AI summary
A fault injection test method of a fault injection test apparatus connected to a vehicle through a debugger is provided. The fault injection test method includes receiving fault injection conditions from a user; and setting the fault injection conditions using an on-chip debugging system (OCDS) module built into a central processing unit (CPU) of the vehicle controller.