Rolling Test Bench Interface for Reusable ECU Harness Emulation
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Solution Overview
Problem
Existing test benches for electronic devices, particularly vehicle ECUs, are complex, costly, and not reusable, leading to increased waste and hindered data collection from realistic conditions due to their complexity and lack of integration within vehicles.
Innovation Solution
A rolling test bench with adaptable interfaces, including a controller, memory, and bridge, connects electronic devices via connector pins and non-volatile memory to store configuration information, enabling dynamic configuration and emulation of wire harnesses, allowing easy swapping and realistic testing without physical harnesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a custom wire harness is designed for each device configuration, then the testing can be tailored to specific device requirements, but the complexity and cost of the test setup increases significantly
Solution Approach 1:
The patent implements a universal test bench platform that can accommodate multiple different electronic devices through a standardized interface. The test bench includes a universal wire harness that can connect to various devices (ECUs, sensors, actuators) through configurable connector assemblies, eliminating the need for custom wire harnesses for each device type. This multi-functional approach maintains testing customization while significantly reducing complexity.
Solution Approach 2:
The test bench is divided into modular components including a universal wire harness, configurable connector assemblies, and a controller. The connector assemblies can be independently configured and swapped to match different device requirements, allowing the system to maintain adaptability without requiring a completely custom wire harness for each device configuration.
2Reliability
If a stationary test bench is used, then the testing environment is controlled and stable, but the ability to test under realistic vehicle conditions is limited
Solution Approach 1:
The patent transforms the traditional stationary test bench into a mobile rolling test bench that can be positioned within actual vehicles. The test bench includes a controller that can dynamically configure connections through the universal wire harness to match the specific vehicle configuration being tested. This dynamic approach allows the system to maintain testing stability while enabling realistic vehicle condition testing.
Solution Approach 2:
The universal wire harness acts as an intermediary between the test bench and the vehicle's existing wiring system. It provides standardized connection points that interface with vehicle components, allowing the controlled test environment to interact with realistic vehicle conditions without requiring complete redesign of the testing infrastructure.
3Adaptability or versatility
If complex wire harnesses are used for each device, then all connection requirements can be met, but the cost and waste increase due to non-reusability
Solution Approach 1:
The universal wire harness is designed with standardized connectors and configurable connection points that can accommodate multiple different electronic devices and vehicle configurations. This single universal harness replaces multiple device-specific harnesses, enabling reuse across different testing scenarios and significantly reducing material waste while maintaining full device compatibility.
Solution Approach 2:
Instead of discarding custom wire harnesses after each device testing, the universal wire harness is designed to be recovered and reused for different devices and vehicle configurations. The configurable connector assemblies can be repositioned and reconfigured, extending the lifespan of the testing infrastructure and eliminating the waste associated with single-use custom harnesses.
Data Source
AI summary
Systems, methods, and other embodiments described herein relate to improving the testing of electronic devices using a rolling test bench with adaptable interfaces. In one embodiment, an interface system includes an endpoint interface device connected with a wire harness of a vehicle. The interface system includes a test device connected with the endpoint interface device via a network to control a component of the vehicle attached to the network via the wire harness and the endpoint interface device.