Multiplexed Automotive Controller Testing for Full DUT Line Coverage
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Solution Overview
Problem
Current portable testing devices for automotive controllers, particularly Body Controller Modules (BCMs), are unable to efficiently test multiple Device Under Test (DUT) lines without additional circuitry, making them bulky, expensive, and difficult to transport, as they often exceed airline luggage weight and size limitations and fail to automatically test the large number of DUT lines in modern BCMs.
Innovation Solution
A compact testing device with first and second multiplexers, measurement modules, stimulation blocks, and channel switches, controlled by a controller, which allows for selective connection and stimulation of DUT lines, enabling efficient testing of various signal types and line configurations, including analog, digital, and bus lines, within a single IO card format.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional testing devices are used to test all DUT lines, then testing coverage is complete, but device size and weight increase making it non-portable
Solution Approach 1:
The testing device is divided into a host computer that runs testing software and a separate I/O card that handles signal I/O operations. This segmentation allows the heavy processing functions to be separated from the portable testing hardware, enabling complete testing coverage while maintaining portability of the physical device.
Solution Approach 2:
The I/O card is designed with universal functionality to handle multiple types of DUT lines (analog, digital, bus lines) through a single device interface. By integrating multiplexers, measurement modules, and stimulation blocks into one universal card, the device can test all line types without requiring separate specialized equipment for each type.
2Measurement precision
If multiple DUT lines are tested simultaneously with dedicated circuitry, then testing accuracy is maintained, but device complexity and cost increase
Solution Approach 1:
The I/O card employs dynamic multiplexing where a single measurement module and stimulation block are time-shared across multiple DUT lines through programmable multiplexers. This dynamic switching allows the same hardware resources to serve multiple lines sequentially, maintaining measurement precision while dramatically reducing the complexity of dedicated circuitry for each line.
Solution Approach 2:
Multiplexers are introduced as intermediary components that bridge the gap between the limited measurement/stimulation modules and the multiple DUT lines. These intermediaries enable single modules to interface with multiple lines by selectively connecting them, thereby maintaining testing accuracy without requiring direct dedicated connections for each line.
3Volume of moving object
If portable testing devices are designed to be compact, then transportability is improved, but testing capability for multiple DUT lines is reduced
Solution Approach 1:
The testing capability is extended from the physical dimension to the software dimension. The I/O card provides compact hardware for portability, while the host computer runs comprehensive testing software that enables full testing capability for all DUT lines. This dimensional shift moves complex testing logic from hardware to software, allowing compact hardware design without sacrificing testing versatility.
Data Source
Figure 1
AI summary
A testing device (1) for an automotive controller, including: plurality of Device Under Test (DUT) lines (3) for connection to respective DUT lines in the automotive controller, and first and second multiplexers (6a,6b) for selecting individual DUT lines. First and second measurement modules (7a,7b) are connected to the multiplexers (6a,6b) for measuring signal characteristics on the selected DUT lines. An interconnect circuit (14) is operable for selectively connecting stimulation modules (11,12,13) to the measurement modules (7a,7b) for stimulating electrical signals on the selected DUT lines (3). A controller (18) is provided to control the switching of the multiplexers (6a,6b) and the interconnect circuit (14) and for receiving the measured signal characteristics from the first and second measurement modules (7a,7b) for testing the respective DUT lines in the automotive controller.