Customer Solutions

Developing a Test System for Intelligent Automotive Components

Author(s):

Thomas Leibner, S.E.A. Datentechnik Gmb; Gerd Schmitz , S.E.A. Datentechnik Gmb

Industry:

Automotive

Product:

CAN, Data Acquisition, NI TestStand, PXI/CompactPCI, Profibus, Signal Conditioning

The Challenge:

Creating a system to test intelligent electronic control units (ECUs) that can support quality assurance during development and production and flexible enough to meet the specific requirements of the customer.

The Solution:

Using NI TestStand, PXI, SCXI, Profibus, and CAN as the foundation for an automotive component test platform (ACTP) to create a flexible, rapid, and reliable test system for ECUs.

Quality Assurance and Functional Testing of ECUs
The ACTP is a powerful system for quality assurance and functional testing of ECUs and electronic modules (ECMs) in the automotive industry. The hardware level and our integrated hardware and software system, TestMaster, provide a compact solution, including flexibility, ease of operation, and rugged design. It ensures high system efficiency and reliably, with scalability of ACTP, we can continuously perform development tests right down to the final production inspection.

Modular Hardware Design for Diverse Applications
The standard hardware component of the ACTP is the National Instruments PXI modular industrial computer. For control and data acquisition purposes, we use PXI in conjunction with SCXI modules in signal preconditioning, for electrically decoupling the specimen from the test system. Its modular design makes the ACTP ideal for diverse applications, ranging from the process development testing to functional tests on the production floor. We achieve this high flexibility by integrating external measuring devices via standard interfaces, such as IEEE 488.2 in laboratory environments or Profibus for manufacturing applications. In combination with the interface adapter, we can customize ACTP to virtually any purpose or requirement. Distinctive properties result from the hardware coupling of NI-CAN and discrete signals by RTSI Bus, which permits unique switching and response time measurements in the millisecond range. Both are increasingly required in advanced development environments.

Developing Software for Broad Testing Needs
We based the ACTP system software on our TestMaster suite for a broad range of testing needs in development and manufacturing. Similar to advanced operating systems, system hardware abstraction is a key feature of the TestMaster solution. Regardless of the physical signaling situation, we identify all signals by name and signal class throughout the system. Similar to the printer control process under Windows, we actuate hardware via appropriate functions and operating surfaces in conjunction with the signal name. As a result, test sequence definitions become largely independent of the hardware used.

This approach effectively helps to protect investments while facilitating upgrades and the transfer of test instructions. We can easily expand the basic functions with a straightforward code interface to suit specific customer requirements.

Clearly arranged MMI screens, providing maximum monitoring and operation, operate the test system. We can also easily expand and reconfigure MMI features to meet special application needs. We define access to the testing system via the integrated user administration functions. Interactively determined parameter settings are simple to apply to the automatic sequence. An application-oriented sequence language facilitates the input of complex sequences. A convenient sequence editor allows users without programming skills to define tests as well.

TestStand, a National Instruments product with numerous configuration options for the optimization of test sequences, controls and executes the testing. Apart from the standard predefined tests, an optional stochastic testing module is available.

To ensure system consistency and appropriate test follow-up capabilities, we manage test instructions and results on a version-controlled basis in an SQL database. Distributed client or server solutions are available as an option. For use in a product environment, the optional integration of a process database is possible. Interfacing with an existing data infrastructure is also feasible.

Conclusions
We based the software of the ACTP on our TestMaster suite, a solution proven in numerous industrial production and R&D testing applications. ACTP is suitable for testing diverse electronic components and modules used in automotive engineering environments, including steering column modules. We can combine it with other test procedures, including noise or vibration measurements, as well as with advanced image processing techniques.

For more information, contact:
Linder Höhe
51147 Köln
Germany
Phone: +49-2203–6992-0
Fax: +49-2203–6992 12
Mail: sea@sea-gmbh.com
Web: www.sea-gmbh.com