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System Design of Automated Test Equipment for Electrical Control Units in Trucks
KTH, School of Electrical Engineering (EES), Micro and Nanosystems.
2014 (English)Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

The high level of complexity in today’s electronic systems increases the demands on an advanced validation and verification process. Automated testing facilitates and improves regression testing (rerun of previously executed test cases to uncover and track new bugs) with increased coverage and reduced costs as a result. 

A vehicle contains multiple control units, each responsible for a specific part: the engine, brakes, gearbox etc. These intelligent systems must be tested thoroughly to ensure correct behavior - both under normal circumstances and when the vehicle is exposed to unexpected events such as electrical failure (short circuit, broken cables etc.). A breakout box, BOB, is a piece of testing equipment that can be used to induce electrical faults on the wiring of the control units. It is typically operated manually. The objective of this project is to develop an automated version, an ABOB. 

A prototype that could induce various faults on arbitrary cables of a control unit was developed. The faults were: short circuit to a variable voltage source with connected or disconnected load, replacement of real signals with simulated ones and open load. The breakout box also performed internal measurements and supplied the user with feedback information about whether or not the test case was successfully executed. Several generations of the system were developed, where the final product had hardware support for up to six connected ECU ports and the possibility to distribute control signals to 256 different ECU ports via a computer based application and a set of communicating microprocessors. 

This thesis project focuses on the software design of the ABOB. For further explanation of the hardware, the reader is advised to consult the report Hardware Synthesis of Automated Electrical Fault Testing in Trucks by Martin Orre.

Abstract [sv]

Komplexiteten i dagens elektroniska system ställer höga krav på verifierings- och valideringsmetoder. Testautomatisering underlättar och förbättrar regressionstestning (upprepning av tidigare utförda testfall för att upptäcka och spåra nya buggar) med ökad testtäckning och reducerade kostnader som följd. 

I ett fordon sitter ett flertal styrenheter vars ansvarsområden varierar: styrning utav motor, bromsar, växellåda osv. För att säkra att dessa enheter fungerar som de ska måste de testas noggrant - dels under normala förhållanden men också då de utsätts för påfrestningar såsom elektriska fel (kortslutning, avbrott osv.). En breakout box, BOB, är en typ av testutrustning vars syfte är att inducera fel på kablaget till styrenheter. Den sköts vanligtvis manuellt. Syftet med det här projektet är att ta fram en automatiserad breakout box, en ABOB. 

En prototyp som kunde inducera ett antal olika fel på godtyckliga kablar kopplade till en styrenhet togs fram. Felen var: kortslutning mot en variabel spänningskälla, simulering av en felaktig signal samt avbrott på kabel. Systemet hade också en återkopplingsmekanism som informerade användaren om huruvida ett testfall hade exekverats på korrekt sätt eller ej. Ett flertal generationer av hård- och mjukvarulösningar utvecklades, där den slutgiltiga produkten hade hårdvarustöd för upp till sex inkopplade ECU-portar och möjlighet att via en datorbaserad applikation samt ett nät av kommunicerande mikroprocessorer distribuera styrsignaler till upp till 256 ECU-portar. 

Detta examensarbete behandlar framtagningen av mjukvara för systemet. Den intresserade läsaren rekommenderas att även ta del av rapporten Hardware Synthesis of Automated Electrical Fault Testing in Trucks av Martin Orre, för kompletterande information om hårdvaran.

Place, publisher, year, edition, pages
2014. , 72 p.
Series
EES Examensarbete / Master Thesis, XR-EE-MST 2014:004
Keyword [en]
test equpment control trucks
National Category
Electrical Engineering, Electronic Engineering, Information Engineering
Identifiers
URN: urn:nbn:se:kth:diva-157531OAI: oai:DiVA.org:kth-157531DiVA: diva2:770508
External cooperation
Scania
Subject / course
Electrical Measurements
Educational program
Master of Science in Engineering - Electrical Engineering
Presentation
Q2, Osquldas väg 10, Stockholm (Swedish)
Supervisors
Examiners
Available from: 2014-12-19 Created: 2014-12-10 Last updated: 2014-12-19Bibliographically approved

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