摘要
能源危机的日趋严峻、排放法规的日趋严格，使得电控高压共轨系统的应用逐渐广泛，为柴油机和车辆的性能优化提供了发挥空间。但同时其又是复杂的机电一体化控制系统，知识范围涵盖了电子学、控制系统、流体力学、燃烧理论等众多方面，使得故障发生后，普通维修人员由于知识面不足，无法或不能满足维修要求。
课题开发了GD-1电控高压共轨柴油机的智能诊断系统，包括电喷系统非排放相关故障在线自诊断、排放相关故障在线自诊断（OBD）以及诊断工具指导性维修建议等内容，构建了完整的电控柴油机故障维修体系，无需或很少需要人工干预，可以自动在线诊断出几乎所有电喷系统故障、以及一些机械系统故障，有效的降低了售后服务市场对于维修人员的知识水平要求，提高了维修效率，顺应了电喷发动机行业潮流，主要研究内容包括：
1自主开发了硬件在环仿真设备（HIL），通过对国外先进电喷系统的深入测试，结合对SAE J2012法规的要求，构建了课题研究的基本框架，更为重要的是，课题在此框架基础上，扩充了众多更加适应于国内市场应用特色的诊断功能，由此解决了课题“做什么？”的问题。
2分析了诊断学领域的众多主流诊断方法，结合故障在线诊断功能的实时、准确、鲁棒性要求，课题提出了基于信号特征和证据融合的专家系统诊断理论，解决了课题“怎么做？”的问题。
3提出了二级诊断的规范，也即各传感器信号在用于电喷控制功能计算前，都要经过第一级诊断和第二级诊断步骤，第一级诊断用于对传感器信号的物理特征进行判断，可以诊断出几乎所有的、由于信号线路故障引起的传感器信息错误；第二级诊断借助车辆或发动机行驶过程中固有的逻辑与经验，用于对传感器信号的逻辑可信度进行判断，可以诊断出大部分的、由于传感器损坏而导致的信号错误。两级诊断规范的采纳，保证了燃油喷射计算所用到的各传感器信息的准确性。
4针对故障在线诊断策略的标定过程，提出了以统计分析为主的标定规范，且统计样本的选取采用了分层不重复抽样的措施，将标定过程转化为抽取电喷组件样本对关键参数进行统计求值的过程。该标定规范的提出，有效地避免了标定人员由于经验的不足而导致的标定错误。
5提出了预先报警、以养代修的诊断思路，降低维修成本、提高运行安全性。包含下述两方面特点：
在发动机（或车辆）启动前就能够预先对相关故障进行报警，避免了车辆带故障运行可能导致的驾驶危险性；电喷系统故障发生早期就能够进行报警，避免了故障严重恶化后导致的系统彻底损坏。
6课题首次在国内构建了完整的OBD诊断框架和细节。提出基于知识的初选以及ESC排放试验的方法，用于确定OBD相关故障项目；明确指出OBD故障包含电控燃油喷射系统、进气管理系统以及排放后处理系统等组件故障；针对电控燃油喷射组件，课题OBD项目包含CPU、TPU、硬件监视狗以及喷油驱动模块故障、喷油器驱动回路诊断、轨压信号漂移诊断等内容，其中喷油器驱动回路故障部位的精确定位以及待机工况下的诊断为课题为满足国内应用特色而专门开发；针对进气管理系统，课题OBD项目包含增压压力信号诊断、进气质量流量信号诊断以及增压后进气管脱落诊断等内容，其中增压压力信号漂移诊断和增压后管路脱落诊断均为国外先进系统所不具备功能，是课题为满足国内应用特色而专门开发；针对排放后处理系统，课题OBD项目包含尿素溶液状态监控、加热电路驱动回路监控、排温状态监控、尿素供给泵驱动回路监控、尿素喷射阀驱动回路监控等内容，考虑到国内部分区域尿素品质较差的现状，容易导致尿素喷射阀卡滞等故障，扩充了国外系统所不具备的尿素喷射阀卡滞故障诊断功能。
7在电喷系统发生故障后，诊断系统采取失效保护策略替代正常情况下的相关功能，失效保护策略的设计原则为，兼顾故障后的继续驾驶性、驾驶安全性并避免排放进一步恶化，并起到了督促驾驶员尽快检修的目的。
8为了降低对维修人员知识水平的要求及维修过程复杂性，课题开发了针对售后服务市场的故障诊断工具，在硬件选择、软件功能编制上均着眼于售后市场应用特点，不仅可以完成常规的读取、清除、记录故障代码，运行状态、冻结桢记录等诊断功能，还开发了指导性维修建议功能（GSS），从故障现象入手、结合故障代码，指导维修人员合理采用智能测试功能，结合分层及分模块化的诊断思路，减少了维修时间、成本，提高了维修效率。
9经过硬件在环、发动机台架和装车道路试验，课题进行了详细的故障在线诊断功能验证，结果显示，课题开发的故障自诊断系统可以较好的完成在线诊断任务，且诊断工具也能满足售后服务市场的使用需求。
Increasingly severity of energy crisis and stringency of exhaust gaslegislation, make electronic controlled common rail system being usedwidely, which gives a chance for performance optimizing of diesel engineand vehicle propelled by such an engine. But as common rail system is a verycomplicated control system, referenced to electronics, control theory,hydrodynamics and combustion theory, it is very difficult for normal serviceman to repair it with high efficiency as scarcity of relative knowledge.
This project created intelligence diagnosis system for GD-1electroniccontrolled common rail engine, including on board detection of non-relativeemission faults, on board diagnosis (OBD) of emission relative faults anddiagnostic tool with Guidance Service suggestion (GSS) function. Without orwith little help from service man, intelligence diagnosis system can detectalmost all of electronic controlled component faults and some machine faults,which reduce the knowledge requirements of normal service man and giveadvantages to aftermarket services. So, intelligence diagnosis system is thelatest trend of fault detection domain of electronic controlled common railengine. Following are the main aspects of this project:
1Hardware in loop equipment are developed, through which, diagnosisfunctions of foreign advanced electronic controlled fuel injection systemhave been tested deeply, at the same time, with the help of SAE J2012legislation, main frame of GD-1diagnosis system has been constructed. Moreimportant, a lot of diagnosis functions which are more comply with chineseaftermarket characteristics are added to this frame, so, the question of ‘Whatto do?’ of this project has been found out.
2A lot of theories of diagnosis domain have been studied, consideringthe real time, exactness and robustness requirements of on board diagnosissystem, this project created a diagnosis theory named as experts system basedon signal character and muti-data fusing method, through which, the questionof ‘How to do?’ of this project has been found out.
3Two level diagnosis criterion has been created, which means that allsensor signals are under the monitor of first and second level diagnosismodules. First level diagnosis module is used to check the physical character of sensor input signal, which can detect almost all of the circuit faults of thatsensor. Second level diagnosis module is used to detect the sensor signalpausibilty using some running logic of engine or vehicle, these kinds of faultsare often caused by function failures of sensor. Two level diagnosis criterionmake the diagnosis conclusion more credible.
4For the calibration of diagnosis strategy, statistic analysis calibrationcriterion are created, during which, method of stratified sampling withoutrepeating is adopted in order to reduce average error of sampling. So,calibration can be changed to sampling and calculation for main parameters.It can effectively avoid the mistakes during calibration process caused byscarcity of experience for some fresh calibration engineer.
5Fault forecast theory has been created, which can make maintenanceto replace most of repairs, and also can reduce repair costs, enhance the drivesafety. Fault forecast theory include following two characteristics:
Faults of some components could be detected before the running ofvehicle or engine, which avoid the danger if running with these faults;
Faults of some components could be detected during early phase, whichavoid the whole damage after the deterioration of these faults.
6OBD frame and details of electronic controlled diesel engine arecreated for the firist time in inland, and lots of them are more comlpy withchinese after markets than those advanced foreign system, they are:
In order to affirm and choose OBD items with little test costs, method ofraw choice based on experts’ knowledge and ESC emission test cycle areused, it is conclusion that, faults of fuel injection system, inlet airmanagement system and emission after treatment system are belong to OBDitems.
For the fuel injection system, OBD faults could present in CPU, TPU,watch dog, injection driven module, driven circuits of injector, rail pressuresensor, and etc. For example, this project can judge accurate positions ofinjector driven circuits and can complete it at station mode;
For inlet air management system, OBD faults could present in boostpressure signal, inlet air mass flow signal, and break out at inlet pipe aftersupercharger. Boost pressure signal drift and inlet pipe break out detectionfunctions are more comlpy with chinese after markets;
For emission after treatment system, OBD faults could present in ureaquality, heating driven circuit, exaust temperature sensor, dosing valve and its driven circuit. Considering urea quality of some area is not good enoughin China, which can cause the dosing valve sticking, so, new function todetect this kind of valve stuck fault is created in this project.
7After failure of electronic components, special strategies are triggeredto make sure of drive safety and continuity, when this faults is emissionrelated, these strategies can give attention to avoid exhaust level deteriorationat the same time.
8In order to keep the integrality of diagnosis system of electroniccontrolled diesel engine, diagnostic tool was developed to be used ataftermarket, the software and hardware of it are chosen specially for servicecharacteristic.
The diagnostic tool can not only read, clear and record diagnostictrouble codes, monitor running parameters, but also can detect faultsintelligently, which pay more attention to machine components. GSSfunction is integrated to diagnostic tool, which can guide maintain man toadopt intelligence diagnosis process appropriately to reduce service time.
9After lots of tests on hardware in loop, engine rig and vehicle, thispaper made detailed validation of on board diagnosis system, which showsthat, it can detect faults effectively, and diagnostic tool can also do great helpto service at aftermarket.
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