汽车车身控制器自动测试系统的设计与实现
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摘要
随着汽车工业的发展,电子控制装置越来越多地在现代汽车中使用。车身控制器是重要的汽车电子控制装置之一,包括中央门锁控制、电动车窗控制、防盗报警控制、灯光控制、安全气囊控制、雨刮器控制等。现阶段,国内许多生产厂家已经能够自主设计汽车车身控制器,并已投入批量生产。但其产品的测试还停留在人工测试的水品上,影响了整体生产效率。因此,开发一套汽车车身控制器的自动测试系统成为必然。
本文以汽车车身控制器自动测试系统的开发为基础,建立了一种基于功能验证的测试模型。该模型将多输入多输出(MIMO, Multiple Input Multiple Output)结构的被测系统根据不同功能简化为若干多输入单输出(MISO, Multiple Input Single Output)结构的功能块,并根据该模型提出一种用于生成测试序列的最短路径算法。
整个测试系统基于虚拟仪器技术构建。在硬件上,采用以工控机为控制核心,以数据采集卡为I/O设备构建硬件平台,组态灵活,通用性好;在软件上,使用LabWindows/ CVI作为测试软件开发环境,图形界面友好,编程快速、方便。
本文解决了汽车BCM测试系统在硬件设计上的关键技术,主要解决了在非车载环境下对电机负载的模拟问题和大电流的检测问题。模拟负载采用了并联达林顿管与功率电阻连接的模拟电子负载结构形式,对大电流的检测使用了霍尔电流传感器。另外,考虑到测试系统的通用性,设计了汽车BCM与数据采集卡连接的接口电路以及汽车BCM与计算机间进行数据交换的通讯电路。
在测试软件开发中,本文解决了在LabWindows/CVI环境下非NI公司数据采集卡的控制问题以及实时多任务处理问题。对数据采集卡的控制主要采用动态链接库技术,通过调用数据采集卡在VC环境下的库函数来实现;实时多任务处理主要采用多线程技术实现了数据的实时采集与显示,以及自动测试的过程控制。
本文最后介绍了所开发的这套测试系统。从实际使用情况看,该测试系统达到了预期的设计要求。
With the development of modern IT, electronic control device are increasingly used in modern automobiles. Body control module is one of the most important electronic control devices of automobile, including central lock control, electric glass control, guard against theft and alarm control, light control, airbag control and rain brush control etc. Nowadays, Body Control Module (BCM) can be designed independently in domestic manufacturers and also be manufactured in batches. Nevertheless, the situation that the test of products is in the level of manual test seriously restricts the total production efficiency. It is necessary to develop an automatic test system of body control module for automobiles.
For the purpose of functional validation this paper establishes a test model for the BCM of automobiles. In the model, a multiple input and multiple output (MIMO) structured system is decomposed into several multiple input and single output (MISO) structured modules. A shortest path-searching algorithm used to generate test sequence is also proposed according to the test model.
The whole test system is constructed using Virtual Instrument techniques. On the aspect of hardware, using industrial PC as its control device and PC-DAQ card as its I/O device makes it easy to reconfigurate the test platform. On the aspect of software, LabWindows/CVI is used as a development tool for the test application software, which provides friendly GUI and convenient programming environment.
Some key problems in developing the hardware system of the BCM test equipment are solved in this paper, including the analog of motor load under off-vehicle circumstance and strong current detection. Parallel connected Darlington transistor and power resistor are used as basic structure for analog load. The Hall current sensor is used to detect strong current. In addition, considering the system reconfiguration, the interface circuit from BCM to PC-DAQ card, as well as the communication circuit for data exchange from BCM to IPC is designed.
During the development of test software, the thesis solves the control problem of DAQ card not produced by NI Company, as well as the problem of handing real time multitasks. Dynamic Link Library technique is used to call the functions provided for the VC environment. Multithread technique is used to realize real time data sampling and displaying, as well as the automatic test process control.
Finally, the developed BCM automatic test system is introduced. The real world applications of the BCM test results demonstrate that the developed system meets design specifications and satisfies customs demands.
本文以汽车车身控制器自动测试系统的开发为基础,建立了一种基于功能验证的测试模型。该模型将多输入多输出(MIMO, Multiple Input Multiple Output)结构的被测系统根据不同功能简化为若干多输入单输出(MISO, Multiple Input Single Output)结构的功能块,并根据该模型提出一种用于生成测试序列的最短路径算法。
整个测试系统基于虚拟仪器技术构建。在硬件上,采用以工控机为控制核心,以数据采集卡为I/O设备构建硬件平台,组态灵活,通用性好;在软件上,使用LabWindows/ CVI作为测试软件开发环境,图形界面友好,编程快速、方便。
本文解决了汽车BCM测试系统在硬件设计上的关键技术,主要解决了在非车载环境下对电机负载的模拟问题和大电流的检测问题。模拟负载采用了并联达林顿管与功率电阻连接的模拟电子负载结构形式,对大电流的检测使用了霍尔电流传感器。另外,考虑到测试系统的通用性,设计了汽车BCM与数据采集卡连接的接口电路以及汽车BCM与计算机间进行数据交换的通讯电路。
在测试软件开发中,本文解决了在LabWindows/CVI环境下非NI公司数据采集卡的控制问题以及实时多任务处理问题。对数据采集卡的控制主要采用动态链接库技术,通过调用数据采集卡在VC环境下的库函数来实现;实时多任务处理主要采用多线程技术实现了数据的实时采集与显示,以及自动测试的过程控制。
本文最后介绍了所开发的这套测试系统。从实际使用情况看,该测试系统达到了预期的设计要求。
With the development of modern IT, electronic control device are increasingly used in modern automobiles. Body control module is one of the most important electronic control devices of automobile, including central lock control, electric glass control, guard against theft and alarm control, light control, airbag control and rain brush control etc. Nowadays, Body Control Module (BCM) can be designed independently in domestic manufacturers and also be manufactured in batches. Nevertheless, the situation that the test of products is in the level of manual test seriously restricts the total production efficiency. It is necessary to develop an automatic test system of body control module for automobiles.
For the purpose of functional validation this paper establishes a test model for the BCM of automobiles. In the model, a multiple input and multiple output (MIMO) structured system is decomposed into several multiple input and single output (MISO) structured modules. A shortest path-searching algorithm used to generate test sequence is also proposed according to the test model.
The whole test system is constructed using Virtual Instrument techniques. On the aspect of hardware, using industrial PC as its control device and PC-DAQ card as its I/O device makes it easy to reconfigurate the test platform. On the aspect of software, LabWindows/CVI is used as a development tool for the test application software, which provides friendly GUI and convenient programming environment.
Some key problems in developing the hardware system of the BCM test equipment are solved in this paper, including the analog of motor load under off-vehicle circumstance and strong current detection. Parallel connected Darlington transistor and power resistor are used as basic structure for analog load. The Hall current sensor is used to detect strong current. In addition, considering the system reconfiguration, the interface circuit from BCM to PC-DAQ card, as well as the communication circuit for data exchange from BCM to IPC is designed.
During the development of test software, the thesis solves the control problem of DAQ card not produced by NI Company, as well as the problem of handing real time multitasks. Dynamic Link Library technique is used to call the functions provided for the VC environment. Multithread technique is used to realize real time data sampling and displaying, as well as the automatic test process control.
Finally, the developed BCM automatic test system is introduced. The real world applications of the BCM test results demonstrate that the developed system meets design specifications and satisfies customs demands.
引文
[1]徐哲.我国汽车电子产业发展现状及对策研究.工业技术经济,2006,25 (2):106~108.
[2]龚进峰,曹健,袁大宏.浅谈我国汽车电子产业现状及发展建议.汽车工程,2004,26 (3):363~366.
[3]罗云汉,周泉.汽车电控技术——ECU制造过程概述(Ⅱ).汽车电器,2002,2:60~62.
[4]赵中原,王建生,邱毓昌.虚拟仪器技术的发展.高压电器,2000,5:36~39.
[5]金晓红.基于虚拟仪器的汽车ABS检测试验台测控系统研究:[硕士学位论文].吉林:吉林大学,2006.
[6]张毅刚,彭喜元,姜守达等.自动测试系统.哈尔滨:哈尔滨工业大学出版社,2001.
[7]田雨.ATE测试平台通用性与故障诊断的研究与实现:[硕士学位论文].成都:电子科技大学,2005.
[8]严一平.虚拟仪器技术和发展趋势.上海计量测试,2005,3:16~23.
[9]刘君华.基于LabWindows/CVI的虚拟仪器设计.北京:电子工业出版社,2003.
[10]秦云川,徐大专,李彤.测量仪器总线技术的发展与现状.中国仪器仪表,2005,8:48~52.
[11]刘君华,申忠如,郭福田.现代测试技术与系统集成.北京:电子工业出版社,2004.
[12]余成波,冯丽辉,潘盛辉.虚拟仪器技术与设计.重庆:重庆大学出版社,2006.
[13]张小牛,侯国屏.虚拟仪器技术回顾与展望.测控技术,2000, 19(9):22~24.
[14]刘歆.数字电路的故障测试模式生成方法研究:[博士学位论文].武汉:华中科技大学,2005.
[15]徐健茹.电路板通用自动测试系统设计与技术研究:[硕士学位论文].西安:西北工业大学,2001.
[16] E. J. McCluskey and N. B. Nesbat, Design for Autonomous Test, IEEE Trans. Comput. 1987, Vol. 30: 866~875.
[17] J. M. Galey, R. E. Norby, and J. P. Roth, Techniques for the Diagnosis of Switching Circuit Failure, in R. S. Ledley, editor, Proc. of the Second Annual Symp. on Switching Circuit Theory and Logic Design, (Detroit), AIEE, Oct. 1961, 152~160.
[18] J. P. Roth, Diagnosis of Automata Failures: A Calculus and a Method, IBM Journal of Computers, and Development, Vol. 10, 1966, No. 4, 278~291.
[19] P. Goel, An implicit enumeration algorithm to generate tests for combinational logic circuits, in Proc. of International Fault-Tolerant Computing Symp. Aug, 1980, 145~151.
[20] P. Goel, An implicit enumeration algorithm to generate tests for combinational logic circuits, IEEE Trans. On Computers, Vol. C-30, 1981, No.3, 215~222.
[21] H. Fujiwara, FAN: A Fanout-Oriented Test Pattern Generation Algorithm, in Proc. of the International Symp. on Circuits and Systems, July, 1985, 671~674.
[22] H. Fujiwara and T. Shimono, On the acceleration of test generation algorithm, IEEE Trans. on Computers, Vol. C32, No.12, 1983, 1137~1144.
[23] H. Fujiwara and T. Shimono, On the acceleration of test generation algorithm, in Proc. of the International Fault-Tolerant Computing Symp. June, 1983, 98~105.
[24]卢开澄,卢华明.图论及其应用(第二版).北京:清华大学出版社,1995.
[25] Kasyanov, V. N.Graph theory for programmers: Algorithms for processing trees.北京:科学出版社,2006.
[26] Tutte, W. T.Graph Theory.Beijing: China Machine Press,2004.
[27] I-Lin Wang, Ellis L. Johnson, and Joel S. Sokol. A Multiple Pairs Shortest Path Algorithm, Transportation Science. Nov, 2005, 39, 465~ 476.
[28]李卫华,谢珩.关于电子模拟负载研究现状的探讨.新余高专学报,2005, 10(2):47~49.
[29]李泽勇,王文生.闭环霍尔电流传感器在车用电源系统中的应用.电子元器件应用,2004, 6(5):25~26,35.
[30] SAE. On-Board Diagnostics for Light and Medium Duty Vehicles Standards Manual, 1999.
[31]过锡隽.汽车电控系统J1939协议和诊断通信模块的开发:[硕士学位论文].杭州:浙江大学,2006.
[32]宋国民,季晓华.基于K线的电控系统诊断平台开发.现代车用动力,2004,2:1~3.
[33]李华刚,殷跃红,徐文超等.基于K线的汽车天窗马达ECU通讯系统的设计.电子技术应用,2007,1:77~80.
[34]张毅,周绍磊,杨秀霞.虚拟仪器技术分析与应用.北京:机械工业出版社,2004.
[35]张发启,江勇,成立等.现代测试技术及应用.西安:西安电子科技大学出版社,2005.
[36]薛原.基于LabWindows/CVI平台的虚拟仪器设计与开发:[硕士学位论文].沈阳:东北大学,2005.
[37]张毅刚、乔立岩.虚拟仪器软件开发环境LabWindows/CVI 6.0编程指南.北京:机械工业出版社,2002.
[38]孙宁,刘洁瑜,钱培贤.多线程技术在加速度计数据采集中的实现.国外电子测量技术,2006,25(5):37~39,42.
[39]宋宇峰.LabWindows/CVI逐步深入与开发实例.北京:机械工业出版社,2003.
[40]林君.虚拟仪器原理及应用.北京:科学出版社,2006.
[41] Jing Feng, Junxi Wang, Jun Zhong, et al. Research and Development of a New Calibration Tool for Electronically Controlled Engine Based on KWP2000. Journal of Shanghai Jiaotong University. Vo1. E-8, No.2, 2003, 197~ 201.
[42] 1SO/W D 14230-2. Keyword protocol 2000-Part 2: Data link layer.
[2]龚进峰,曹健,袁大宏.浅谈我国汽车电子产业现状及发展建议.汽车工程,2004,26 (3):363~366.
[3]罗云汉,周泉.汽车电控技术——ECU制造过程概述(Ⅱ).汽车电器,2002,2:60~62.
[4]赵中原,王建生,邱毓昌.虚拟仪器技术的发展.高压电器,2000,5:36~39.
[5]金晓红.基于虚拟仪器的汽车ABS检测试验台测控系统研究:[硕士学位论文].吉林:吉林大学,2006.
[6]张毅刚,彭喜元,姜守达等.自动测试系统.哈尔滨:哈尔滨工业大学出版社,2001.
[7]田雨.ATE测试平台通用性与故障诊断的研究与实现:[硕士学位论文].成都:电子科技大学,2005.
[8]严一平.虚拟仪器技术和发展趋势.上海计量测试,2005,3:16~23.
[9]刘君华.基于LabWindows/CVI的虚拟仪器设计.北京:电子工业出版社,2003.
[10]秦云川,徐大专,李彤.测量仪器总线技术的发展与现状.中国仪器仪表,2005,8:48~52.
[11]刘君华,申忠如,郭福田.现代测试技术与系统集成.北京:电子工业出版社,2004.
[12]余成波,冯丽辉,潘盛辉.虚拟仪器技术与设计.重庆:重庆大学出版社,2006.
[13]张小牛,侯国屏.虚拟仪器技术回顾与展望.测控技术,2000, 19(9):22~24.
[14]刘歆.数字电路的故障测试模式生成方法研究:[博士学位论文].武汉:华中科技大学,2005.
[15]徐健茹.电路板通用自动测试系统设计与技术研究:[硕士学位论文].西安:西北工业大学,2001.
[16] E. J. McCluskey and N. B. Nesbat, Design for Autonomous Test, IEEE Trans. Comput. 1987, Vol. 30: 866~875.
[17] J. M. Galey, R. E. Norby, and J. P. Roth, Techniques for the Diagnosis of Switching Circuit Failure, in R. S. Ledley, editor, Proc. of the Second Annual Symp. on Switching Circuit Theory and Logic Design, (Detroit), AIEE, Oct. 1961, 152~160.
[18] J. P. Roth, Diagnosis of Automata Failures: A Calculus and a Method, IBM Journal of Computers, and Development, Vol. 10, 1966, No. 4, 278~291.
[19] P. Goel, An implicit enumeration algorithm to generate tests for combinational logic circuits, in Proc. of International Fault-Tolerant Computing Symp. Aug, 1980, 145~151.
[20] P. Goel, An implicit enumeration algorithm to generate tests for combinational logic circuits, IEEE Trans. On Computers, Vol. C-30, 1981, No.3, 215~222.
[21] H. Fujiwara, FAN: A Fanout-Oriented Test Pattern Generation Algorithm, in Proc. of the International Symp. on Circuits and Systems, July, 1985, 671~674.
[22] H. Fujiwara and T. Shimono, On the acceleration of test generation algorithm, IEEE Trans. on Computers, Vol. C32, No.12, 1983, 1137~1144.
[23] H. Fujiwara and T. Shimono, On the acceleration of test generation algorithm, in Proc. of the International Fault-Tolerant Computing Symp. June, 1983, 98~105.
[24]卢开澄,卢华明.图论及其应用(第二版).北京:清华大学出版社,1995.
[25] Kasyanov, V. N.Graph theory for programmers: Algorithms for processing trees.北京:科学出版社,2006.
[26] Tutte, W. T.Graph Theory.Beijing: China Machine Press,2004.
[27] I-Lin Wang, Ellis L. Johnson, and Joel S. Sokol. A Multiple Pairs Shortest Path Algorithm, Transportation Science. Nov, 2005, 39, 465~ 476.
[28]李卫华,谢珩.关于电子模拟负载研究现状的探讨.新余高专学报,2005, 10(2):47~49.
[29]李泽勇,王文生.闭环霍尔电流传感器在车用电源系统中的应用.电子元器件应用,2004, 6(5):25~26,35.
[30] SAE. On-Board Diagnostics for Light and Medium Duty Vehicles Standards Manual, 1999.
[31]过锡隽.汽车电控系统J1939协议和诊断通信模块的开发:[硕士学位论文].杭州:浙江大学,2006.
[32]宋国民,季晓华.基于K线的电控系统诊断平台开发.现代车用动力,2004,2:1~3.
[33]李华刚,殷跃红,徐文超等.基于K线的汽车天窗马达ECU通讯系统的设计.电子技术应用,2007,1:77~80.
[34]张毅,周绍磊,杨秀霞.虚拟仪器技术分析与应用.北京:机械工业出版社,2004.
[35]张发启,江勇,成立等.现代测试技术及应用.西安:西安电子科技大学出版社,2005.
[36]薛原.基于LabWindows/CVI平台的虚拟仪器设计与开发:[硕士学位论文].沈阳:东北大学,2005.
[37]张毅刚、乔立岩.虚拟仪器软件开发环境LabWindows/CVI 6.0编程指南.北京:机械工业出版社,2002.
[38]孙宁,刘洁瑜,钱培贤.多线程技术在加速度计数据采集中的实现.国外电子测量技术,2006,25(5):37~39,42.
[39]宋宇峰.LabWindows/CVI逐步深入与开发实例.北京:机械工业出版社,2003.
[40]林君.虚拟仪器原理及应用.北京:科学出版社,2006.
[41] Jing Feng, Junxi Wang, Jun Zhong, et al. Research and Development of a New Calibration Tool for Electronically Controlled Engine Based on KWP2000. Journal of Shanghai Jiaotong University. Vo1. E-8, No.2, 2003, 197~ 201.
[42] 1SO/W D 14230-2. Keyword protocol 2000-Part 2: Data link layer.