Fault type
It is not difficult to find that at the controller level, various components can be further abstracted into sensors, communications, controllers, actuators, and mechanical systems. This is the starting point for automobile fault diagnosis, that is, to diagnose faults for ECUs and what faults to diagnose. According to this idea, ECU faults are usually divided into 5 types:
• Mechanical/system failure, mainly refers to the failure of mechanical components or system failure caused by various factors. Take the failure involved in the above-mentioned engine control functional unit as an example, such as engine piston cylinder damage, engine operating temperature is too high, etc.
• Electronic and electrical failures mainly refer to failures of sensors and actuators; for example, temperature sensor signal loss or solenoid valve burnout.
• Hardware failure mainly refers to the failure of the controller and various chips on the PCB; for example, the solenoid valve driver chip reports overvoltage or undervoltage failures.
• Software failure, mainly refers to ECU software failure, such as dead loop, division by zero, overflow, etc.;
• Communication failures mainly refer to communication interruption, communication stop and communication data error, etc. For example, CAN communication signal timeout and other failures.
In order to have a more comprehensive understanding of the above five types of faults, we will take the position sensor as an example to explain this type of fault in electronic appliances.
Consider what the failures are from two perspectives.
On the one hand, from the supply voltage, whether it is undervoltage, overvoltage, short-circuited to ground or open-circuited, or short-circuited to the power supply. For example, according to the specification of the position sensor:
The voltage is less than 4.75V, which is undervoltage;
The voltage is greater than 5.25V, which is considered overvoltage;
The voltage is less than 1V, which means the power supply is short-circuited to the ground or open;
If the voltage is greater than 6V, it means the power supply is short-circuited to the power supply.
On the other hand, from the perspective of the PWM signal, whether the duty cycle of the PWM signal is within the valid range, and whether the PWM signal is blocked. For example, according to the specification of the position sensor:
The valid range of PWM signal duty cycle is [2%, 98%]. If the PWM signal duty cycle is lower than 2%, or higher than 98%, the PWM signal duty cycle is invalid.
The valid range of PWM signal frequency is [1kHz, 3kHz]. If the PWM signal frequency is lower than 1kHz, or if the PWM signal frequency is higher than 3kHz, the PWM signal frequency is invalid.
How to effectively manage so many faults? Use Diagnostic Trouble Code (DTC), which is a digital universal identifier of fault conditions identified by the car's online diagnostic system.
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Professor at Beihang University, dedicated to promoting microcontrollers and embedded systems for over 20 years.
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