技术领域technical field
本发明涉及一种汽车故障方法及装置，尤其是涉及一种基于半物理仿真的诊断汽车电控单元故障的方法及装置。The invention relates to a method and a device for an automobile fault, in particular to a method and a device for diagnosing a fault of an electric control unit of an automobile based on semi-physical simulation.
背景技术Background technique
汽车电控系统的故障诊断一般是通过汽车上专用故障诊断接口，用解码器读取来自汽车ECU(电控单元)输出的故障码，对故障码进行解释，显示故障内容。这种诊断模式是一种被动读取故障的诊断模式，不能对ECU的内部故障和动态故障进行诊断。汽车ECU故障码可以有以下几个方面产生：1、传感器本身故障，即传感器不能正常工作；2、信号传送介质故障，即汽车线束短路和电路故障；3、ECU内部硬件故障；4、ECU内部软件故障。The fault diagnosis of the automobile electronic control system is generally through the special fault diagnosis interface on the car, and the decoder is used to read the fault code output from the automobile ECU (electronic control unit), explain the fault code, and display the fault content. This diagnosis mode is a passive reading fault diagnosis mode, and cannot diagnose the internal faults and dynamic faults of the ECU. Automotive ECU fault codes can be generated in the following aspects: 1. The sensor itself is faulty, that is, the sensor cannot work normally; 2. The signal transmission medium is faulty, that is, the car wiring harness is short-circuited and the circuit is faulty; 3. Internal hardware faults in the ECU; 4. Internal ECU Software failure.
实际上，ECU本身故障率不小：ECU硬件故障包括其引出脚的短路或短路等；ECU软件故障，例如控制程序及参数丢失导致的错误控制以及由此产生的故障码等，造成汽车常常出现无码有故障、有码无故障，以及故障码与故障不对应等问题，使汽车维修人员无法根据解码器读出的故障码直接判定汽车故障部件及原因。目前业内普遍采用“替代法”，即，针对故障码指示的汽车电控系统故障范围，采用合格零部件，从外围(包括传感器、执行器和相关线束)开始进行一一替代。若某合格部件替代后故障消失，则该部件即为故障源；若所有替代均无效，最后才推断为ECU故障。由于汽车传感器和执行器安装位置十分狭小和紧凑，线束铺设和走向十分复杂，有时因没有合格的替代部件需订货而延迟修理，且姗姗来迟的配件未必是故障根本原因。显而易见，这种维修方式不但花费大量人力和时间，还必须库存包括ECU在内的大量合格零部件。汽车修理企业所修车型越多，所需库存的备件也就越多，占用的流动资金量也就越大。In fact, the failure rate of ECU itself is not small: ECU hardware failure includes short circuit or short circuit of its pins; ECU software failure, such as wrong control caused by loss of control program and parameters, and resulting fault codes, etc. There are faults without codes, there are no faults with codes, and fault codes do not correspond to faults, etc., making it impossible for car maintenance personnel to directly determine the faulty parts and causes of the car based on the fault codes read by the decoder. At present, the industry generally adopts the "substitution method", that is, for the fault range of the automotive electronic control system indicated by the fault code, use qualified parts and replace them one by one from the periphery (including sensors, actuators and related wiring harnesses). If the fault disappears after a qualified component is replaced, the component is the source of the fault; if all the replacements are invalid, it is finally inferred that the ECU is faulty. Due to the narrow and compact installation locations of automotive sensors and actuators, the laying and routing of wiring harnesses is very complicated. Sometimes repairs are delayed because there are no qualified replacement parts to order, and the late arrival of accessories may not be the root cause of the failure. Obviously, this maintenance method not only takes a lot of manpower and time, but also must stock a large number of qualified parts including ECU. The more models repaired by auto repair companies, the more spare parts they need to store, and the greater the amount of working capital they occupy.
发明内容Contents of the invention
本发明的目的就是为了克服上述现有技术存在的缺陷而提供一种不仅大大简化汽车电控系统故障的排查流程，缩小故障排查范围，而且还提高了故障诊断率，并有效减少替代部件诊断所带来的维修工作量和库存部件资金占有量，从而大大降低维修成本的基于半物理仿真的诊断汽车电控单元故障的方法及装置。The purpose of the present invention is to overcome the above-mentioned defects in the prior art and provide a method that not only greatly simplifies the troubleshooting process of the automotive electronic control system, narrows the scope of troubleshooting, but also improves the rate of fault diagnosis and effectively reduces the time required for diagnosis of replacement parts. The method and device for diagnosing the failure of an automobile electronic control unit based on semi-physical simulation greatly reduces the maintenance workload and the capital occupation of inventory components, thereby greatly reducing the maintenance cost.
本发明的目的可以通过以下技术方案来实现：基于半物理仿真的诊断汽车电控单元故障的方法，其特征在于，该方法包括以下步骤：The object of the present invention can be achieved through the following technical solutions: the method for diagnosing the fault of the automobile electric control unit based on semi-physical simulation, it is characterized in that, the method comprises the following steps:
1)测试人员通过人机交互界面选择标准数据库中的一个设定工况；1) The tester selects a set working condition in the standard database through the human-computer interaction interface;
2)高速处理PC机将该工况所对应的标准输入信息通过仿真控制器发送给待检电控单元，同时将该工况所对应的标准输出响应信息送入故障诊断及显示模块中的随机存贮器；2) The high-speed processing PC sends the standard input information corresponding to the working condition to the electronic control unit to be checked through the simulation controller, and at the same time sends the standard output response information corresponding to the working condition to the random fault diagnosis and display module. memory;
3)待检电控单元对标准输入信息进行处理，产生待检电控单元输出响应信息经仿真控制器输送到故障诊断及显示模块中的随机存贮器；3) The electronic control unit to be checked processes the standard input information to generate output response information of the electronic control unit to be checked, which is sent to the random memory in the fault diagnosis and display module through the simulation controller;
4)故障诊断及显示模块将标准输出响应信息与待检电控单元输出响应信息进行比对，并判断待检电控单元所有输出响应是否在设定的允许偏差范围内，如果判断为是则在显示器中显示待检电控单元正常，否则显示待检电控单元存在故障，并进行步骤5)；4) The fault diagnosis and display module compares the standard output response information with the output response information of the electronic control unit to be checked, and judges whether all the output responses of the electronic control unit to be checked are within the set allowable deviation range. The display shows that the electronic control unit to be checked is normal, otherwise it is displayed that the electronic control unit to be checked has a fault, and proceed to step 5);
5)测试人员改变某输入信息；5) The tester changes some input information;
6)高速处理PC机监控及人机交互模块将工况输入信息发送给仿真控制器，仿真控制器通过高速数据接口向待检电控单元发送经D/A转换的传感器模拟信号、控制开关信号以及发动机此时的相位信号，待检电控单元输出驱动控制信号，驱动控制信号由仿真控制器采集后送回高速处理PC机；6) The high-speed processing PC monitoring and human-computer interaction module sends the working condition input information to the simulation controller, and the simulation controller sends the D/A converted sensor analog signal and control switch signal to the electronic control unit to be checked through the high-speed data interface As well as the phase signal of the engine at this time, the electronic control unit to be inspected outputs the drive control signal, and the drive control signal is collected by the simulation controller and sent back to the high-speed processing PC;
7)高速处理PC机调用与待检电控单元对应的发动机模型，向其输入驱动控制信号，发动机模型仿真计算出模拟转速及其他控制参量，将这些信号通过仿真控制器高速数据接口再输送给待检电控单元，待检电控单元运行后输出的驱动控制信号再反馈给高速处理PC机的发动机模型，重复步骤7)直到待检电控单元各输出信号稳定；7) The high-speed processing PC calls the engine model corresponding to the electronic control unit to be checked, and inputs the driving control signal to it, and the engine model simulates and calculates the simulated speed and other control parameters, and then sends these signals to the high-speed data interface of the simulation controller. The electronic control unit to be checked, the drive control signal outputted after the electronic control unit to be checked is running is fed back to the engine model of the high-speed processing PC, and step 7) is repeated until each output signal of the electronic control unit to be checked is stable;
8)测试人员改变某输入信息，实时观测显示屏对应输出的改变，根据待检电控单元的控制策略，诊断出待检电控单元的故障性质。8) The tester changes a certain input information, observes the change of the corresponding output of the display screen in real time, and diagnoses the fault nature of the electronic control unit to be checked according to the control strategy of the electronic control unit to be checked.
所述的步骤1)中的标准数据库的建立包括以下步骤：The establishment of the standard database in described step 1) comprises the following steps:
11)高速处理PC机调用标准数据库读入功能，采集已知标准目标电控单元的输出，并将该工况的输入与标准目标电控单元的输出进行系统标识，建立对应的标准电控单元输入-输出；11) The high-speed processing PC calls the standard database reading function, collects the output of the known standard target electronic control unit, and performs system identification on the input of this working condition and the output of the standard target electronic control unit, and establishes the corresponding standard electronic control unit input Output;
12)采样多个同型号的已知标准目标电控单元在步骤11)所述的输入下的标准输出，得到标准输出的允许偏差；12) sampling the standard output of a plurality of known standard target electronic control units of the same model under the input described in step 11), to obtain the allowable deviation of the standard output;
13)改变步骤11)中的设定工况，即改变已知标准目标电控单元的输入，重复步骤11)和步骤12)，由此建立同一工况下输入-输出及允许偏差相关联的标准数据库。13) Change the set working condition in step 11), that is, change the input of the known standard target electronic control unit, repeat step 11) and step 12), thereby establishing the relationship between input-output and allowable deviation under the same working condition standard database.
所述的步骤8)中的输入信息包括节气门开度、发动机负荷、水温、油温、空调开关、变速器档位。The input information in step 8) includes throttle opening, engine load, water temperature, oil temperature, air conditioner switch, transmission gear.
所述的步骤12)中的多个同型号的已知标准目标电控单元优选3～5个。There are preferably 3 to 5 known standard target electronic control units of the same type in the step 12).
基于半物理仿真的诊断汽车电控单元故障的装置，其特征在于，该装置包括PC机及控制系统、USB CAN转换器、仿真控制器。所述的PC机控制系统包括高速处理PC机、监控及人机交互模块、发动机仿真模型模块、标准数据库模块、故障诊断及显示模块。所述的高速处理PC机通过总线控制监控及人机交互模块、发动机仿真模型模块、标准数据库模块、故障诊断及显示模块；所述的PC机及控制系统通过USB CAN转换器与仿真控制器连接。The device for diagnosing the failure of an automobile electronic control unit based on semi-physical simulation is characterized in that the device includes a PC, a control system, a USB CAN converter, and a simulation controller. The PC control system includes high-speed processing PC, monitoring and human-computer interaction module, engine simulation model module, standard database module, fault diagnosis and display module. The high-speed processing PC controls the monitoring and human-computer interaction module, the engine simulation model module, the standard database module, the fault diagnosis and display module through the bus; the PC and the control system are connected to the simulation controller through the USB CAN converter .
所述的仿真控制器包括至少两路可编程开关量或频率量输出电路、多路可编程D/A输出电路、多路可编程I/O输出电路、多路I/O输入电路、多路A/D输入电路，以及高速数据接口，所述的仿真控制器通过高速数据接口与待检电控单元连接。The simulation controller includes at least two programmable switching or frequency output circuits, multiple programmable D/A output circuits, multiple programmable I/O output circuits, multiple I/O input circuits, multiple A/D input circuit, and a high-speed data interface, the simulation controller is connected with the electronic control unit to be checked through the high-speed data interface.
所述的故障诊断及显示模块包括随机存储器、内部数据存储器、比较器。The fault diagnosis and display module includes a random access memory, an internal data memory and a comparator.
与现有技术相比，本发明具有以下优点：Compared with the prior art, the present invention has the following advantages:
1、运用本发明，实现汽车电控单元ECU离车诊断，不仅大大简化汽车电控系统故障的排查流程，缩小故障排查范围，而且还提高了故障诊断率，并有效减少替代部件诊断所带来的维修工作量和库存部件资金占有量。1. Using the present invention to realize the off-vehicle diagnosis of the automotive electronic control unit ECU, not only greatly simplifies the troubleshooting process of the automotive electronic control system, narrows the scope of troubleshooting, but also improves the fault diagnosis rate and effectively reduces the problems caused by the diagnosis of replacement parts. The maintenance workload and capital occupation of inventory parts.
2、本发明采用数字仿真发动机模型替代真实发动机及其运行环境，当发动机仿真模型与真实汽车电控单元(简称目标ECU)联机，进行实时仿真模拟运行时，该系统可被视为一“黑箱”。采用一已知标准ECU作为目标ECU，在设定工况下进行标准ECU输入-输出参量的系统标识，建立标准ECU输入-输出数据库。2. The present invention adopts the digital simulation engine model to replace the real engine and its operating environment. When the engine simulation model is connected with the real automobile electronic control unit (referred to as the target ECU) for real-time simulation operation, the system can be regarded as a "black box" ". Use a known standard ECU as the target ECU, carry out the system identification of the input-output parameters of the standard ECU under the set working conditions, and establish the input-output database of the standard ECU.
3、本发明通过在ECU输入端输入满足其正常工作所需信号，检测ECU各输出响应信号，并以标准ECU工作状态各输出响应为参照，通过一一比对标准与故障待检ECU输出信号某些特征指标，判断待检ECU输出是否在设定的允许偏差范围内，若所有输出均在各自设定偏差内，则表示待检ECU正常；反之若超出该范围，即表示待检ECU存在故障，进而判断汽车电控ECU故障性质。对部分ECU软件故障，可在原汽车制造厂的帮助下，通过重新读入控制程序和参数加以修复；对部分ECU硬件故障(如引出脚松脱等)，运用适当工具加以修复，从而大大降低维修成本。3. The present invention detects each output response signal of the ECU by inputting the signal required for its normal operation at the input end of the ECU, and takes each output response of the standard ECU working state as a reference, and compares the output signal of the standard and the ECU to be checked for failure one by one Some characteristic indicators determine whether the output of the ECU to be inspected is within the set allowable deviation range. If all outputs are within the respective set deviations, it means that the ECU to be inspected is normal; otherwise, if it exceeds this range, it means that the ECU to be inspected exists. fault, and then judge the nature of the fault of the automotive electronic control ECU. For some ECU software failures, it can be repaired by re-reading the control program and parameters with the help of the original automobile manufacturer; for some ECU hardware failures (such as loose pins, etc.), use appropriate tools to repair them, thereby greatly reducing maintenance. cost.
4、通过在本发明装置界面动态改变ECU某输入信号，实时显示其相关输出，根据该电控ECU的控制策略，可以准确诊断出ECU故障的性质。4. By dynamically changing a certain input signal of the ECU on the interface of the device of the present invention and displaying its related output in real time, according to the control strategy of the electronically controlled ECU, the nature of the ECU fault can be accurately diagnosed.
附图说明Description of drawings
图1为本发明方法的流程图；Fig. 1 is the flowchart of the inventive method;
图2为本发明的结构示意图。Fig. 2 is a structural schematic diagram of the present invention.
具体实施方式Detailed ways
下面结合附图和具体实施例对本发明进行详细说明。The present invention will be described in detail below in conjunction with the accompanying drawings and specific embodiments.
实施例Example
如图1所示，基于半物理仿真的诊断汽车电控单元故障的方法，该方法包括以下步骤：As shown in Figure 1, the method for diagnosing the fault of an automobile electronic control unit based on semi-physical simulation, the method includes the following steps:
步骤101)测试人员通过人机交互界面选择标准数据库中的一个设定工况。标准数据库的建立包括以下步骤：11)高速处理PC机调用标准数据库读入功能，采集已知标准目标电控单元的输出，并将该工况的输入与标准目标电控单元的输出进行系统标识，建立对应的标准电控单元输入-输出；12)采样3～5个同型号的已知标准目标电控单元在步骤11)所述的输入下的标准输出，得到标准输出的允许偏差；13)改变步骤11)中所设定的工况，即改变已知标准目标电控单元的输入，重复步骤11)和步骤12)，由此建立同一工况下输入-输出及允许偏差相关联的标准数据库。Step 101) The tester selects a set working condition in the standard database through the man-machine interface. The establishment of the standard database includes the following steps: 11) The high-speed processing PC calls the standard database read-in function, collects the output of the known standard target electronic control unit, and performs system identification on the input of this working condition and the output of the standard target electronic control unit , establish the corresponding standard electronic control unit input-output; 12) sample the standard output of 3 to 5 known standard target electronic control units of the same model under the input described in step 11), and obtain the allowable deviation of the standard output; 13 ) change the working condition set in step 11), that is, change the input of the known standard target electronic control unit, repeat step 11) and step 12), thus establishing the relationship between input-output and allowable deviation under the same working condition standard database.
步骤102)高速处理PC机将该工况所对应的标准输入信息通过仿真控制器发送给待检电控单元，同时将该工况所对应的标准输出响应信息送入故障诊断及显示模块中的随机存贮器；Step 102) The high-speed processing PC sends the standard input information corresponding to the working condition to the electronic control unit to be checked through the simulation controller, and simultaneously sends the standard output response information corresponding to the working condition to the fault diagnosis and display module. RAM;
步骤103)待检电控单元对标准输入信息进行处理，其所产生的输出响应信息由仿真控制器采集后输送到故障诊断及显示模块中的随机存贮器；Step 103) The electronic control unit to be checked processes the standard input information, and the output response information generated by it is collected by the simulation controller and sent to the random memory in the fault diagnosis and display module;
步骤104)故障诊断及显示模块将标准输出响应信息与待检电控单元输出响应信息进行比对，并判断待检电控单元输出响应是否在设定的允许偏差范围内，如果判断为是则在显示器中显示待检电控单元正常，否则显示待检电控单元存在故障，并进行步骤105)；Step 104) The fault diagnosis and display module compares the standard output response information with the output response information of the electronic control unit to be checked, and judges whether the output response of the electronic control unit to be checked is within the set allowable deviation range, if it is judged to be yes, then It is normal to display the electronic control unit to be checked in the display, otherwise it is displayed that the electronic control unit to be checked has a fault, and proceed to step 105);
步骤105)测试人员改变某输入信息；Step 105) the tester changes certain input information;
步骤106)高速处理PC机监控及人机交互模块将工况输入信息发送给仿真控制器，仿真控制器通过高速数据接口向待检电控单元发送经D/A转换的传感器模拟信号、控制开关信号以及发动机此时的相位信号，待检电控单元输出驱动控制信号，仿真控制器采集这些驱动控制信号后送回高速处理PC机；Step 106) The high-speed processing PC monitoring and human-computer interaction module sends the working condition input information to the simulation controller, and the simulation controller sends the D/A converted sensor analog signal and control switch to the electronic control unit to be checked through the high-speed data interface signal and the phase signal of the engine at this time, the electronic control unit to be tested outputs the drive control signal, and the simulation controller collects these drive control signals and sends them back to the high-speed processing PC;
步骤107)高速处理PC机调用待检电控单元所对应的发动机模型，向其输入驱动控制信号，发动机模型进行数字仿真运算，得到模拟转速及其他控制参量，将这些信号通过仿真控制器高速数据接口再输送给待检电控单元，待检电控单元输出的驱动控制信号再反馈给高速处理PC机的发动机模型，重复步骤107)直到待检电控单元各输出信号稳定；Step 107) The high-speed processing PC calls the engine model corresponding to the electronic control unit to be checked, and inputs the drive control signal to it, and the engine model performs digital simulation operations to obtain simulated speed and other control parameters, and these signals are passed through the high-speed data of the simulation controller. The interface is delivered to the electronic control unit to be checked again, and the drive control signal output by the electronic control unit to be checked is fed back to the engine model of the high-speed processing PC, and step 107) is repeated until each output signal of the electronic control unit to be checked is stable;
步骤108)测试人员改变某输入信息如节气门开度、发动机负荷、水温、油温、空调开关、变速器档位，实时观测显示屏对应输出的改变，根据待检电控单元的控制策略，诊断出待检电控单元的故障性质。Step 108) The tester changes certain input information such as throttle opening, engine load, water temperature, oil temperature, air conditioner switch, transmission gear, observes the corresponding output changes of the display screen in real time, and diagnoses Find out the fault nature of the electronic control unit to be checked.
如图2所示，基于半物理仿真的诊断汽车电控单元故障的装置，该装置包括PC机及控制系统1、USB CAN转换器2、仿真控制器3。PC机及控制系统1包括高速处理PC机11、监控及人机交互模块12、发动机仿真模型模块13、标准数据库模块14、故障诊断及显示模块15。高速处理PC机11通过总线控制监控及人机交互模块12、发动机仿真模型模块13、标准数据库模块14、故障诊断及显示模块15。PC机及控制系统1通过USB CAN转换器2与仿真控制器3连接。仿真控制器3包括至少两路可编程开关量输出电路、多路可编程D/A输出电路、多路可编程I/O输出电路、多路I/O输入电路、多路A/D输入电路，以及高速数据接口。仿真控制器3通过高速数据接口与待检电控单元4连接。故障诊断及显示模块15包括随机存储器、内部数据存储器、比较器。As shown in Figure 2, the device for diagnosing the fault of the electronic control unit of an automobile based on semi-physical simulation includes a PC and a control system 1, a USB CAN converter 2, and a simulation controller 3. The PC and control system 1 includes a high-speed processing PC 11 , a monitoring and human-computer interaction module 12 , an engine simulation model module 13 , a standard database module 14 , and a fault diagnosis and display module 15 . The high-speed processing PC 11 controls the monitoring and human-computer interaction module 12 , the engine simulation model module 13 , the standard database module 14 , and the fault diagnosis and display module 15 through the bus. The PC and the control system 1 are connected with the simulation controller 3 through the USB CAN converter 2 . The simulation controller 3 includes at least two programmable switch output circuits, multiple programmable D/A output circuits, multiple programmable I/O output circuits, multiple I/O input circuits, and multiple A/D input circuits , and a high-speed data interface. The simulation controller 3 is connected with the electronic control unit 4 to be checked through a high-speed data interface. Fault diagnosis and display module 15 includes random access memory, internal data memory and comparator.
基于半物理仿真的诊断汽车电控单元故障的装置，用数字仿真发动机模型替代真实发动机及其运行环境，当其与真实汽车电控单元(简称目标ECU)联机后，实时仿真模拟运行，通过检测目标ECU的输出并与标准ECU输出比较，实现对目标ECU的故障诊断。本发明装置设有“模拟运行”、“建立数据库”“诊断”三种工作模式：A device for diagnosing faults in automotive electronic control units based on semi-physical simulation. The digital simulation engine model is used to replace the real engine and its operating environment. When it is connected to the real automotive electronic control unit (referred to as the target ECU), the real-time simulation runs and passes the test. The output of the target ECU is compared with the output of the standard ECU to realize the fault diagnosis of the target ECU. The device of the present invention is provided with three working modes of "simulation operation", "establishment of database" and "diagnosis":
在“模拟运行”时，PC机监控及人机交互模块首先将装置界面上测试人员设定工况输入(如，节气门开度、发动机负荷、水温、油温、空调开关、变速器档位等)发送给仿真控制器；仿真控制器通过高速数据接口向目标ECU发送经D/A转换的传感器模拟信号、控制开关信号以及发动机此时的相位信号(凸轮轴位置传感器信号和曲轴转速传感器信号)，同时不断接收目标ECU输出的喷油、点火等驱动控制信号，并发送回高速处理PC机；高速处理PC机调用发动机模型仿真模拟得到其模拟转速及其他控制参量，将这些信号通过仿真控制器数据接口再送给目标ECU，ECU的输出再反馈给高速处理PC机的发动机模型……，若干循环后，目标ECU各输出信号稳定。通过实时显示窗口，可清晰地看到目标ECU模拟运行中输出的喷油、点火等主要波形。当在人机交互界面改变某输入信号，实时观测显示屏对应输出的改变，根据目标ECU的控制策略，可以准确推断ECU的故障性质。During the "simulation operation", the PC monitoring and human-computer interaction module first inputs the operating conditions set by the tester on the device interface (such as throttle opening, engine load, water temperature, oil temperature, air-conditioning switch, transmission gear, etc. ) to the simulation controller; the simulation controller sends the D/A converted sensor analog signal, control switch signal and engine phase signal (camshaft position sensor signal and crankshaft speed sensor signal) to the target ECU through the high-speed data interface At the same time, it continuously receives the drive control signals such as fuel injection and ignition output by the target ECU, and sends them back to the high-speed processing PC; the high-speed processing PC calls the engine model simulation to obtain its simulated speed and other control parameters, and passes these signals through the simulation controller The data interface is sent to the target ECU, and the output of the ECU is fed back to the engine model of the high-speed processing PC... After several cycles, the output signals of the target ECU are stable. Through the real-time display window, you can clearly see the main waveforms such as fuel injection and ignition output during the simulation operation of the target ECU. When a certain input signal is changed on the human-computer interaction interface, the corresponding output change of the display screen is observed in real time, and the fault nature of the ECU can be accurately inferred according to the control strategy of the target ECU.
当工作在“建立数据库”状态，高速处理PC机调用标准数据库读入功能，采集已知标准目标ECU的输出，并将该工况的输入与目标ECU的输出进行系统标识，建立标准ECU输入-输出。考虑到同型号标准ECU可能存在一定的输出偏差，采样3～5个完好ECU相同输入下的标准输出，得到标准输出的允许偏差。改变设定工况，即改变ECU的输入，可得到与之相对应的ECU标准输出，由此建立标准ECU输入-输出数据库。When working in the "establish database" state, the high-speed processing PC calls the standard database read-in function, collects the output of the known standard target ECU, and makes system identification between the input of the working condition and the output of the target ECU, and establishes the standard ECU input- output. Considering that the standard ECU of the same model may have a certain output deviation, the standard output of 3 to 5 intact ECUs under the same input is sampled to obtain the allowable deviation of the standard output. Changing the set working conditions, that is, changing the input of the ECU, can obtain the corresponding standard output of the ECU, thereby establishing a standard ECU input-output database.
当工作在“诊断”状态，此时进行故障ECU(简称待检ECU)的诊断，高速处理PC机调用故障诊断及显示模块和标准数据库模块读出功能。测试人员通过人机交互界面选择标准数据库中某设定工况，于是高速处理PC机将该工况下一系列标准输入通过仿真控制器发送给待检ECU，同时将对应的标准输出送入故障诊断及显示模块中的随机存储器，高速处理PC机将接收到的待检ECU输出送入故障诊断及显示模块，进行待检ECU输出与标准ECU输出的比对，若差异都在规定的偏差范围内，认为待检ECU正常；反之，则认为待检ECU故障。诊断结果进入内部数据存贮器并显示故障内容。When working in the "diagnosis" state, the fault ECU (referred to as ECU to be checked for short) is diagnosed, and the high-speed processing PC calls the fault diagnosis and display module and the read function of the standard database module. The tester selects a set working condition in the standard database through the human-computer interaction interface, and then the high-speed processing PC sends a series of standard inputs under the working condition to the ECU to be tested through the simulation controller, and at the same time sends the corresponding standard output to the fault The random access memory in the diagnosis and display module, the high-speed processing PC sends the output of the ECU to be checked to the fault diagnosis and display module, and compares the output of the ECU to be checked with the output of the standard ECU. If the difference is within the specified deviation range , it is considered that the ECU to be inspected is normal; otherwise, it is considered that the ECU to be inspected is faulty. The diagnosis result enters the internal data memory and displays the fault content.
如图2所示，本发明装置用高速处理PC机中的发动机模型实时仿真替代真实发动机及其运行环境，需要检测的真实汽车电控单元(简称目标ECU)通过仿真系统的高速数据接口与高速处理PC机相连。其中的PC机及控制系统、仿真控制器、PC机及控制系统与仿真控制器间信息传递的通讯接口USB CAN等的构成及作用如下：As shown in Figure 2, the device of the present invention replaces the real engine and its operating environment with the real-time simulation of the engine model in the high-speed processing PC. The processing PC is connected. Among them, the composition and function of the PC and control system, the simulation controller, the communication interface USB CAN, etc. for information transmission between the PC and the control system and the simulation controller are as follows:
1、PC机控制单元：1. PC control unit:
高速处理PC机通过总线控制监控及人机交互模块、发动机仿真模型模块、标准数据库模块、故障诊断及显示模块等的运行。The high-speed processing PC controls the operation of the monitoring and human-computer interaction module, engine simulation model module, standard database module, fault diagnosis and display module, etc. through the bus.
●监控及人机交互模块：提供友好的人机交互操作界面，实时显示目标ECU状态输出和诊断结果；根据本发明装置工作状态转换命令，实现调用发动机仿真模型模块进行仿真运算控制、建立ECU标准输入输出数据库(调用数据库读入功能)、故障诊断过程控制(数据库读出以及输出数据实时比对、存储结果和相关显示等)。●Monitoring and human-computer interaction module: provide a friendly human-computer interaction operation interface, and display the target ECU status output and diagnosis results in real time; according to the working status conversion command of the device of the present invention, realize the call of the engine simulation model module for simulation operation control and establish ECU standards Input and output database (calling database read-in function), fault diagnosis process control (database read-out and real-time comparison of output data, storage results and related display, etc.).
●发动机仿真模型：它是整个仿真系统中的虚拟发动机。采用均值发动机模型以准确动态地预测一些发动机必要变量，选用Matlab/Simulink软件进行建模，经RealTime workshop转化为可执行C语言文件，可加快仿真计算。●Engine simulation model: it is a virtual engine in the whole simulation system. The average engine model is used to accurately and dynamically predict some necessary engine variables, and Matlab/Simulink software is used for modeling, which is converted into executable C language files by RealTime workshop, which can speed up simulation calculations.
●标准数据库模块●Standard database module
支持实时读入-读出操作的大容量可读写数据存贮器。Large-capacity readable and writable data memory that supports real-time read-in-readout operations.
●故障诊断及显示模块●Fault diagnosis and display module
由随机存储器和内部数据存储器、比较器等组成。随机存储器主要用于临时存放来自标准ECU数据库中的一些标准输出信号；内部数据存储器则用来存放比较结果信息，并在人机交互接口的窗口中显示。It consists of random access memory, internal data memory, comparator, etc. The random access memory is mainly used to temporarily store some standard output signals from the standard ECU database; the internal data memory is used to store the comparison result information and display it in the window of the human-computer interaction interface.
2、仿真控制器2. Simulation controller
仿真控制器作为目标ECU和PC机控制单元之间的连接接口，应能根据高速处理PC机发送的设定工况要求，模拟产生一系列输入信号发送给目标ECU，驱动ECU工作，同时，仿真控制器不断采集目标ECU输出信号送回高速处理PC机。考虑目标ECU输入-输出信号要求，与之相连接的仿真系统硬件接口应有：As the connection interface between the target ECU and the PC control unit, the simulation controller should be able to simulate and generate a series of input signals and send them to the target ECU according to the high-speed processing set working conditions sent by the PC to drive the ECU to work. At the same time, the simulation The controller continuously collects the target ECU output signal and sends it back to the high-speed processing PC. Considering the target ECU input-output signal requirements, the hardware interface of the simulation system connected to it should have:
●至少2路可编程开关量或频率量输出电路●At least 2 programmable switching or frequency output circuits
根据高速处理PC机送出的转速信号，产生相应的凸轮轴位置传感器和曲轴转速传感器信号并送入目标ECU相应输入端口。According to the speed signal sent by the high-speed processing PC, the corresponding camshaft position sensor and crankshaft speed sensor signals are generated and sent to the corresponding input port of the target ECU.
●多路可编程D/A输出电路●Multi-channel programmable D/A output circuit
根据高速处理PC机送出的各传感器信号(如：节气门位置、冷却水温、进气温度、进气歧管绝对压力等)，产生相应的模拟电压信号并送入目标ECU相应输入端口。According to the high-speed processing of various sensor signals (such as throttle position, cooling water temperature, intake air temperature, intake manifold absolute pressure, etc.) sent by the PC, corresponding analog voltage signals are generated and sent to the corresponding input ports of the target ECU.
●多路可编程I/O输出电路●Multi-channel programmable I/O output circuit
根据高速处理PC机送出的I/O数字信号(如：鈅匙开关、怠速触点开关、空挡开关、空调请求开关、制动开关等)，产生相应的高低电平开关控制信号，并送入目标ECU相应输入端口。According to the high-speed processing of the I/O digital signals sent by the PC (such as key switch, idle contact switch, neutral switch, air conditioner request switch, brake switch, etc.), corresponding high and low level switch control signals are generated and sent to The corresponding input port of the target ECU.
●多路I/O输入电路●Multi-channel I/O input circuit
采集目标ECU输出的驱动继电器开关的高低电平信号经I/O接口转换后，变为数字信号送回高速处理PC机。Collect the high and low level signals of the driving relay switch output by the target ECU and convert them into digital signals and send them back to the high-speed processing PC after being converted by the I/O interface.
●多路A/D输入电路●Multi-channel A/D input circuit
采集ECU输出的模拟量信号，经A/D转换送回高速处理PC机。Collect the analog signal output by the ECU, and send it back to the high-speed processing PC through A/D conversion.
●高速数据接口支持目标ECU与仿真控制器间输入输出信号的高速传输。●High-speed data interface supports high-speed transmission of input and output signals between the target ECU and the simulation controller.
●采集ECU输出的驱动喷油器等电磁阀类的电流信号，经整形滤波化处理后，送回高速处理PC机。●Collect current signals from ECU to drive solenoid valves such as fuel injectors, and send them back to PC for high-speed processing after shaping and filtering.
3、CAN通讯接口——USB CAN转换器3. CAN communication interface - USB CAN converter
采用USB CAN软件驱动程序，实时地向仿真控制器发送高速处理PC机指令，同时接收来自仿真控制器的数据信息，实现PC机控制单元与仿真系统间的通讯。The USB CAN software driver is used to send high-speed processing PC instructions to the simulation controller in real time, and at the same time receive data information from the simulation controller to realize the communication between the PC control unit and the simulation system.
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