Modular Vector VT System for ECU Test Control – Academic

Professionals are shaped through practice, using real tools and practical examples. Academic theory must be complemented by equipment that prepares students for the demands of the professional world, and this is where the automated test control environment from Vector shines: simple, flexible, and powerful, designed to be easy to learn and use.

In today’s academic curriculum, practical demonstrations and hands-on practice must align with current industry standards and technologies to adequately prepare students for their future professional roles. The integration of tools like the Vector VT System into university labs is crucial to this preparation, allowing students to engage with advanced testing systems that mirror real-world applications in automotive and electrical engineering.

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The primary challenge was to develop an automated testing system centred around the Vector VT System that could seamlessly handle both current and future Electronic Control Units (ECUs). This required a highly modular and reconfigurable setup capable of meeting various testing scenarios, ensuring versatility for academic use. Additionally, the system needed to comply with strict international and internal testing standards while remaining accessible and easy for students to operate.

The system had to address the dual objectives of providing flexibility in testing and maintaining robustness in handling advanced parametric and functional testing processes. Moreover, it needed to strike a balance between the complexity required for professional-level testing and the simplicity needed in an academic environment, providing a platform where students can learn the intricacies of ECU testing.

The hardware architecture of the test system was built to ensure scalability and flexibility, essential for the dynamic and evolving demands of ECU testing. The integrated test rack encompasses all the necessary hardware for establishing an automated test and measurement system, complete with the communication interfaces required to test an ECU. A 3KW power supply was included to meet various functional and non-functional voltage and current requirements of the connected ECU. The system also provides several control, measurement, stimulation, and communication options via the VT System, a modular and scalable platform. Adequate cooling was installed to maintain optimal operational temperatures, and a custom break-out panel was developed for flexible reconfiguration of the ECU connections, depending on the testing requirements.

This solution includes the following key components:

  • VT System: the backbone of the testing environment, providing the modular setup for testing and measurement across different ECUs.
  • Power Supply: a reliable 3KW power source that ensures consistent performance for both high-power and low-power testing scenarios.
  • Custom Break-out Panel: this panel serves as an interface for all connectors in the VT System, enabling easy access to digital and analog inputs and outputs, and supporting failure injection points. Its design ensures maximum flexibility, allowing the system to adapt to various test configurations as required.
  • Communication Interfaces: these include FlexRay, CAN, and LIN protocols, along with an electric vehicle charger communication protocol interface. This diversity supports both legacy systems and modern automotive communication technologies, giving students exposure to a broad spectrum of vehicle network systems.
  • Emergency Stop & Cooling System: safety is critical in any testing environment. The emergency stop feature allows for an immediate shutdown in case of an issue, while the cooling system ensures the VT System operates within its optimal temperature range.

This hardware configuration not only establishes a robust and scalable testing environment but also highlights the modularity and adaptability required for university labs, where testing needs frequently change based on academic goals and evolving technologies.

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The software component of the test system plays an equally critical role, providing the interface for test management, hardware control, and data logging. The system was designed around Vector’s CANoe software suite, focusing on providing a seamless integration with the hardware. CANoe offers an intuitive, user-friendly environment that allows students to configure, monitor, and manage testing operations easily.

Key software features include:

  • Automated configuration of test parameters based on the specific ECU being tested.
  • Integration with the Vector VT modules to manage various test sequences.
  • Flexible software modules that enable students to modify and experiment with test configurations, offering valuable hands-on experience in understanding ECU testing processes.
  • Real-time feedback on test results through the user interface, allowing students to observe and interact with live data. This feature also supports custom test scenarios for deeper learning opportunities.

The software’s flexibility and simplicity make it ideal for academic use, ensuring that students can focus on learning the underlying principles of ECU testing without being overwhelmed by overly complex operations.

The configuration used for this VT System includes the following key modules:

  • VT9112: a 19″ subrack housing with backplane VT8012B, providing an organized and expandable structure for integrating VT modules.
  • VT6060: a real-time module powered by an Intel® Core-i7 9850HE processor with ERT support, 32 GB RAM, 120 GB SSD, and various connection interfaces (Ethernet, PCIe, USB3.0), facilitating high-performance testing.
  • VT1104: a load and measurement module for 4 ECU output channels, offering control over relays, internal electronic load, and voltage measurement. This module also supports 48V vehicle power grids, enhancing its versatility.
  • VT7970: a smart charge communication (SCC) module for testing electric vehicle charging systems according to IEC 61851-1, with Qualcomm-based powerline communication for smart charge protocols (ISO 15118).
  • VT2832: a switch matrix module enabling programmable wiring of test systems, allowing flexible setup of test system components within a matrix configuration.
  • VT2848 FPGA: a general-purpose digital I/O module with user-programmable FPGA, offering 48 configurable digital inputs/outputs, adaptable to a variety of test conditions.
  • VT6204B: a network interface module supporting CAN, LIN, and FlexRay protocols across four channels, configurable with CANpiggy, LINpiggy, and FlexRayPiggy modules, providing flexibility for various communication protocols.
  • VT2816A: a general-purpose analog I/O module offering 12 analog measurement inputs and 4 analog outputs, with specific support for current measurement.

Other System Components

  • 27U Open Frame Rack: provides the structure for housing the entire test system.
  • Power Distribution and Control: ensures stable power supply management across the entire system.
  • TDK-Lambda Genesys Gen2U-3300W Power Supply: a laboratory-grade programmable power supply that delivers stable and reliable power for the test system.
  • Custom Break-out Panel: features 160 4mm connection points for reconfigurable testing setups, maximizing flexibility and adaptability for various test configurations. Connections are secured using spade terminals and VT System connectors, optimized for high current-carrying capacity.
  • Emergency Stop & Cooling Systems: provides essential safety mechanisms and operational integrity during extended testing sessions.

The development of this automated Vector ECU Test Control Rack not only adheres to academic and industry standards but also offers a powerful platform for hands-on education. By exposing students to real-world ECU testing, communication protocols, and systems integration, this test system bridges the gap between academic theory and professional engineering practices. It equips the next generation of engineers with critical, practical experience, preparing them to meet the demands of the modern automotive industry.

This test system is not just a tool—it’s a gateway for students to gain valuable experience, aligning academic learning with real-world applications.

 

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