装配图大学生方程式赛车设计(模具及卡具设计)(有cad图+三维图)
装配图大学生方程式赛车设计(模具及卡具设计)(有cad图+三维图),装配,大学生,方程式赛车,设计,模具,卡具,cad,三维
为汽车信息娱乐系统研究的自动化测试系统黄英萍、罗斯麦克莫伦、马克奥克赛跟、甘王特戴赫拉、皮特琼斯、彼得贝内特、亚历山德罗斯、莫扎特可、简凯乐其收到:2009年12月18日/接受:2010年3月12日在线发表:2010年4月15日#施普林格出版社伦敦有限公司2010年摘要 当前的溢价车辆实施的各式各样的信息、娱乐和通信一般称为信息娱乐系统。在汽车的发展期间,信息娱乐测试系统整体一级是常规地进行由专家可以观察一个客户手动出级别。这种方法有明显的限制方面若要测试覆盖率和效力由于的复杂性系统函数和人类的能力。因此,它是为自动化汽车制造商所要求的高度测试系统,将复制人类的信息娱乐系统包括有关感官方式有关的专家控制(即,接触)和观察(即,视线和声音)下测试系统。本白皮书介绍了设计、开发和评价的这种系统,包括基于视觉的车辆网络仿真检查、自动导航功能,随机手摇波形产生、完善的检测和测试自动化。开发的系统是能够:刺激车辆系统跨越多各式各样的初始化条件下,行使的每个函数,请检查系统反应,并为事后检测记录故障情况分析。黄英萍、罗斯麦克莫伦、马克奥克赛跟:甘王特戴赫拉沃里克制造集团,沃里克大学,考文垂工程学院和国际癌症研究机构,沃里克大学英国考文垂体育班尼特,捷豹路虎工程中心关键字:自动测试,信息娱乐系统,图像处理,建模与仿真,回路硬件,鲁棒性,变形简介 信息娱乐系统提供的各种信息,娱乐和通讯功能的车辆司机和乘客。典型的职能是路线的指导,收音机和CD播放、视频等音频娱乐娱乐电视和移动电话的接口等作为以及对用户的相关的接口功能控制系统。一直在这大增长驱动的消费类电子产品的迅速发展的领域和客户期望有这些功能他们的车辆。这是的例子环绕声,DVD娱乐系统,iPod连接,数字无线电和电视和语音激活。与这种增长的功能已在技术上的复杂性相应增加系统。在当前的溢价车辆,信息娱乐系统系统通常实现为一个分布式系统组成的通信通过一个高的模块数目高速光纤网络等媒体导向系统运输(大部分)。在此实现信息娱乐系统系统其实是系统的系统(SOS)与个人系统有了自主权,以实现其功能,但共享资源,如HumanMachine接口(HMI),扬声器和通信通道1。典型这种SOS的问题是突发行为作为系统以意外的方式,特别是在期间进行交互哪里有可能对一些初始化条件在单个系统中获取的延误和失败。这些可能被行使系统。在汽车的发展,扬天的信息娱乐系统是极其重要和按照惯例进行手动的工程师的人可以在客户层面观察,但这与限制一方面要测试覆盖面和有效性。第一次限制是可用来做手动测试的时间,受发展的时间尺度和工程师的约束工作时间。第二个是测试的在重复性,这是受人为错误。因此,有自动化信息娱乐的要求测试的能力,其中复制包括有关人类专家有关控制感官方式(即,触摸和声音)和观察(即,视线和声音)下的系统测试。这种测试功能必须能够刺激各式各样的初始化条件跨系统包括那些被视为根据摇、电池电量低或故障条件下,行使的每个函数,请检查系统响应和记录相关的数据,例如,大多数总线跟踪,在随后的分析故障。这文件描述的设计和发展这种作为一部分的英国学术和工业collabora-系统本族语的说法到复杂系统的验证项目。在于系统中,硬件-中环(HIL)平台受支持的基模型的方法模拟车辆网络实时和动态地提供各类根据测试的信息娱乐系统的重要信号。自针对某些反映系统的响应触摸屏、机器视觉系统的显示是被雇用来监测检验屏幕图案、文字和警告灯告诉-故事的正确性。信息娱乐功能的大多数由访问通过集成的触摸屏幕的用户。为了实现完全自动化的测试,一种新型电阻模拟技术的目的是要模拟操作的触摸屏幕。它是已知该电压瞬变过程,如发动机的启动瞬时电流突可以到达800A,可能会导致在系统上的一些故障。若要测试针对低电压瞬变条件下,系统的稳定性瞬态波形发生器的制定是为了模仿三具体的瞬态过程。测试自动化软件集成并控制所有设备,形成完全自动化测试过程,可以不断地在天运行或甚至一个星期。不只会让开发的测试系统各种测试可能、可重复的并且非常可靠,而且还大大提高了检测效率和简化了的任务繁琐的验证测试。基于模型的功能的电子测试已以实施控制单元(ECU)使用HIL在过去几年的汽车制造商2-5.目前,捷豹路虎(JLR)已通过HIL自动化测试和验证的电子身体系统、动力总成和底盘控制系统6,7。这种技术的好处包括制造工艺(2010)51:233246自动化测试,较早前测试物理原型之前车辆生成、鲁棒性和动态执行能力测试和减少供应商软件迭代。机器视觉系统已在许多生产-使用图灵应用程序如汽车8-10、机器人指导11,和焊接缺陷跟踪12,13。作者还雇用机器视觉的技术高级驱动程序助理系统的障碍检测14,15。然而,没有研究有报道使用机器视觉系统的设计验证测试。验证测试在设计阶段是非常不同从测试中制造。首先,设计验证测试需要覆盖了大量不同的测试用例,而不是限制,设置要证明正确的设计。的时这辆车是在生成测试用例的必由之路早期发展阶段使用基于模型的测试技术,模拟在车辆运行条件真正的时间。第二,设计验证测试要求鲁棒性评价,迭代和重复测试虽然它不需要大批量的零件的进行了测试。第三,设计验证测试需要频繁的为不同类型的汽车测试系统的适应或为同一辆车不同的发展阶段。其中一个新奇的这篇论文是机器的集成远景和HIL技术的复杂设计验证测试。此外,本文件提出一种新型的伪随机生成三个电压瞬变的概念允许模仿随机测试的波形进程作为在实际情况下,见过,并且还可以对测试重新生成,作进一步调查。此外,共同的办法来模仿触摸的操作由一个人类的屏幕是使用机器人武器。在此设计中,狡猾的电阻模拟方法替换机器人要实现这一目标的武器。方法可以完全地通过使用HIL模拟器,在软件中实现因此消除的复杂机械的需要设备,如机器人武器、气动/液压、和电磁致动器。2系统配置为测试开发的系统的配置信息娱乐系统是图中所示1。该系统由组成六个关键要素包括下测试,HIL股测试仪、机器视觉(照相机),触摸的操作屏幕、瞬态波形发生器和自动化测试。根据测试的信息娱乐系统包括一个数包括无线电/CD播放机,模块的放大器(AMP)、导航系统、蓝色牙/电话USB,车辆安装程序、辅助音频接口和气候控制功能。HMI主要基于7TFT电阻控制小组(ICP)在中心控制台和远程在方向盘上的控件。音频输出是通过DSP放大器。模块之间的通信是通过执行控制、数据和音频最光巴士信息。信息娱乐系统连接到通过模块称为ICM作为车辆的其余部分大多数之间的网关和车辆控制器地区网络(CAN)总线。值得注意的是ICP和远程控制方向盘上驻留在该车辆CAN总线。此外,在连接了大多数分析仪在测试过程中的最环。最分析仪是由HIL测试仪通过数字输出,以触发控制日志记录的最大跟踪发生故障时。HIL测试仪模拟测试系统内,车辆网络和动态地提供了各种必要根据测试的信息娱乐系统的信号。它还充当若要控制其他设备的控制中心。例如,它将发送通过串行端口触发相机和接收命令从照相机,检查结果。机器视觉(照相机)系统检查对系统的响应监测触摸屏等模式的显示和文本。触摸屏的操作是通过实现的。使用一种阻力模拟方法,哪个是执行-HIL测试仪中的mented。通过使用此方法的测试系统可以获取大部分的信息娱乐系统功能。瞬态波形生成器生成电压信号和通过的信息娱乐系统通电可编程电源产品供应商。波形发生器,模仿三个电压瞬变过程,用于针对低电压事件测试系统的稳定性。的在要集成的宿主计算机中运行自动化测试和控制所有设备,形成一个完全自动化的测试进程。另外,已经与主机PC通过TCP/IP以太网通信-机器视觉系统扬天。此链接允许存储的时间戳中的图像主机PC这样的测试下单位的行为可以检讨脱机的测试结果。以下各节描述的各个元素的自动化测试系统包括HIL测试仪、基于视觉检验、自动化的触摸屏操作,瞬变波形发生器和测试实验。3、HIL测试仪条目模拟器16用来形成一个硬件-中-半实物仿真试验系统。HIL测试系统模拟车辆CAN总线提供电源模式对大多数网络通过大多数网关的信号。它此外模拟ICP经营的信息娱乐系统。此外,HIL测试仪还提供RS232串行与相机和瞬态进行通信的接口波形发生器、电阻模拟操作触摸屏和A/D接口检测声音和声音频率测量。模拟器由仿真模型组成的条目和如图中所示的扩展硬件2。扩展框中包括一个处理器板DS1006和一个接口板DS2211。DSP板运行的仿真模型,虽然接口板提供了不同的界面链接与其他设备,如罐头,抵抗的产出,A/D转换器、模拟/数字输入和输出和RS232来控制机器视觉系统的串行通信。在HIL系统中,实现了仿真模型在MATLAB/仿真/Stateflows和已编译使用自动C代码生成函数的Matlab的实时实时执行车间。3.1模拟的电源模式信息娱乐系统的行为是由一个称为“电源模式”的罐决定的,例如,指示该车辆的运行状态点火关闭,上,点火发动机摇,引擎运行,等。若要测试性能的信息娱乐系统系统在摇的条件下,根据测试车必须是在当应用摇引擎摇的状态瞬变电压到这辆车。此外,任何后续必须在引擎运行进行功能测试后摇的状态。在真正的赛车,电源模式的消息传送的身体ECU连接到罐头。因为我们在测试上一个测试的信息娱乐系统。有时,为了表示真车的平台生成正确的电源模式行为,我们利用可HIL测试仪来模拟身体ECU的模拟传输功率模式消息到大多数的网关。3.2ICP仿真备信息娱乐系统的集成控件面板为用户提供了一些硬键的操作系统。ICP备控制的职能包括:选择的音频源,加载和弹出CD,向上/向下寻找广播电台和CD曲目、音量控件,依此类推。若要启用这些自动化测试必须的检测中心,由控制职能,ICP备条目实时模拟器。ICP备电子控制单元与车辆的接口通过车辆罐头。因此,模拟ICP单位通过使用的条目模拟器可以模拟。图所示的ICP备仿真模型3.3.3声音检测一个简化的版的仿真模型RS232串行通信是图中所示5。A传输的消息以回车符结束和有10个字节的最大长度。已收到的邮件8个字节的固定的长度。第一次3个字节给出的结果虽然以下5个字节指示结果名称值。例如,积极跟踪号码是缩写形式4基于视觉检查完善的检测包含两个方面即检测声音打开或关闭和检测的频率(统治)声音。声音信号的采样从扬声器作为结束图中所示1,并转换成数字信号的AD内的条目模拟器的转换器。打开/关闭声音确定检查信号的振幅。的声音频率由特定电路的检测模拟器。检测声音频率的目的,是若要确定声音源和积极裁谈会跟踪。3.4模拟的串行通信RS232串行通信用来建立HIL测试仪与相机之间的联系和因此,关闭循环测试的瞬态波形发生器可以执行。在测试期间,HIL测试仪是控制中心指挥相机和瞬变波形发生器和以获得检验结果从他们。例如,相机需要若要选择特定的图像处理作业所吩咐为特定的测试文件。生成的检查结果相机需要返回到HIL测试仪。瞬态波形发生器需要com扔下去砸到生成特定启动波形特定的测试。参数的波形造成故障需要返回到HIL测试人员以便可以在中重复此特定的测试以后的分析阶段。 4.1机器视觉系统机器视觉系统包括一台相机,照明、光学和图像处理软件。康耐视视线彩色视觉传感器17被选择的图像采集和加工,其中提供640480像素的分辨率和32MB的闪存。采集速率的视觉传感器是60全帧每秒。图像采集是通过逐行扫描。图像提供了处理软件(视线在资源管理器Ver4.2.0)宽库的视觉工具用于特征识别核查、测量和测试应用程序。PatMaxTM技术的一部分夹具和先进阅读的光学字符识(OCR)工具文17可在软件中。主照明的来源是从光与LED环定向的前台照明,提供了高对比度之间的对象和背景。所选的内容光学镜头取决于字段的视图和工作距离。在该设置下,镜头焦距为8毫米使用。图像处理任务可以被分配到在摄像机闪存中存储的不同的作业文件。在中组织这项工作,图像处理的工作了根据系统功能与五个作业文件相对应的五个显示页面。每个作业的文件进行所有视觉检查所需的测试页规格。在这次的视觉巡查工作可以分为三类,如下所示。4.2检查的模式绝大多数信息娱乐功能用户可以通过触摸屏操作。因此,大部分的功能测试是检查是否屏幕给出正确像预期的那样显示。例如,我们需要检查页,温度格式,时钟格式,收音机/CD的来源,等等。这种检查可以通过检测在特定的屏幕区域中的模式。图6给检查的主页上显示的示例。最初,主页的左上方模式被训练使用PatMaxTM工具和主控形状图案作为存储。在测试期间,捕获映像从测试下股与受过训练的模式进行比较。页的认识到基于模式匹配返回积分从PatMaxTM工具。如图中所示6首页页有99.9,而其他匹配的得分最高页音频、气候和通讯还有更低匹配的分数。作者也适用帕特MaxTM工具检测的车辆仪器群集。有关如何更详细信息PatMaxTM工具介绍工作7.Int J Adv Manuf Technol (2010) 51:233246DOI 10.1007/s00170-010-2626-2ORIGINAL ARTICLEDevelopment of an automated testing systemfor vehicle infotainment systemYingping Huang & Ross McMurran & Mark Amor-Segan & Gunwant Dhadyalla &R. Peter Jones & Peter Bennett & Alexandros Mouzakitis & Jan KielochReceived: 18 December 2009 / Accepted: 12 March 2010 / Published online: 15 April 2010# Springer-Verlag London Limited 2010Abstract A current premium vehicle is implemented witha variety of information, entertainment, and communicationfunctions, which are generally referred as an infotainmentsystem. During vehicle development, testing of the info-tainment system at an overall level is conventionally carriedout manually by an expert who can observe at a customerlevel. This approach has significant limitations with regardto test coverage and effectiveness due to the complexity ofthe system functions and humans capability. Hence, it ishighly demanded by car manufacturers for an automatedinfotainment testing system, which replicates a humanexpert encompassing relevant sensory modalities relatingto control (i.e., touch) and observation (i.e., sight andsound) of the system under test. This paper describes thedesign, development, and evaluation of such a system thatconsists of simulation of vehicle network, vision-basedinspection, automated navigation of features, randomcranking waveform generation, sound detection, and testautomation. The system developed is able to: stimulate avehicle system across a wide variety of initialisationconditions, exercise each function, check for systemresponses, and record failure situations for post-testinganalysis.Y. Huang (*) : R. McMurran : M. Amor-Segan : G. DhadyallaWarwick Manufacturing Group, University of Warwick,Coventry CV4 7AL, UKe-mail: yingping.huangwarwick.ac.ukR. P. JonesSchool of Engineering and IARC, University of Warwick,Coventry, UKP. Bennett : A. Mouzakitis : J. KielochJaguar Land Rover, Engineering Centre,Coventry, UKKeywords Automatic testing . Infotainment .Image processing . Modeling and simulation .Hardware-in-the-loop . Robustness . Validation1 IntroductionAn infotainment system provides a variety of information,entertainment, and communication functions to a vehiclesdriver and passengers. Typical functions are route guidance,audio entertainment such as radio and CD playback, videoentertainment such as TV and interface to mobile phones, aswell as the related interface functions for the users tocontrol the system. There has been a large growth in thisarea driven by rapid developments in consumer electronicsand the customer expectations to have these functions intheir vehicles. Examples of this are surround sound, DVDentertainment systems, iPod connectivity, digital radio andtelevision, and voice activation.With this growth in features there has been acorresponding increase in the technical complexity ofsystems. In a current premium vehicle, the infotainmentsystem is typically implemented as a distributed systemconsisting of a number of modules communicating via a highspeed fiber optic network such as Media Orientated SystemsTransport (MOST). In this implementation the infotainmentsystem is in fact a System of Systems (SOS) with individualsystems having autonomy to achieve their function, butsharing resources such as the HumanMachine Interface(HMI), speakers, and communication channel 1. Typicalissues with such SOS are emergent behavior as systemsinteract in an unanticipated manner particularly duringsome initialisation conditions where it may be possible toget delays and failures in individual systems. These maynot be readily observable until the particular part of the234system is exercised. During vehicle development, valida-tion of the infotainment system is extremely important andis conventionally carried out manually by engineers whocan observe at a customer level but this has limitations withregard to test coverage and effectiveness. The firstlimitation is the time available to do manual tests, whichis constrained by the development time scale and engineersworking hours. The second is in the repeatability of the test,which is subject to human error. Hence, there is arequirement for an automated infotainment test capability,which replicates a human expert encompassing relevantsensory modalities relating to control (i.e., touch and voice)and observation (i.e., sight and sound) of the system undertest. This test capability must be able to stimulate thesystem across a wide variety of initialisation conditionsincluding those seen under cranking, low battery or faultconditions, exercise each function, check for systemresponses, and record related data, e.g., MOST bus trace,in the case of a malfunction for subsequent analysis. Thispaper describes the design and development of such asystem as part of a UK academic and industrial collabora-tive project into the validation of complex systems.In the system, a Hardware-in-the-Loop (HIL) platformsupported by a model-based approach simulates the vehiclenetwork in real time and dynamically provides variousessential signals to the infotainment system under test. Sincethe responses of the system are majorly reflected in thedisplay of the touch screen, a machine vision system isemployed to monitor the screen for inspection of thecorrectness of the patterns, text, and warning lights/tell-tales.The majority of infotainment functions are accessed by theuser through an integrated touch screen. In order to achieve afully automated testing, a novel resistance simulationtechnique is designed to simulate the operation of the touchscreen. It is known that voltage transient processes, such asengine start where an instantaneous current inrush can reach800 A, may result in some failures on the system. To test thesystem robustness against low voltage transient conditions, atransient waveform generator is developed to mimic threespecific transient processes. A testing automation softwareintegrates and controls all devices to form a fully automatedtest process, which can be run continuously over days oreven weeks. The developed testing system not only makesvarious testing possible, repeatable, and robust, but alsogreatly improves testing efficiency and eases the task oftedious validation testing.Model-based testing of functionality of an ElectronicControl Unit (ECU) using HIL has been implemented byautomotive manufacturers over the last few years 25.Currently, Jaguar Land Rover (JLR) has adopted the HILtechnology for automated testing and validation of elec-tronic body systems, powertrain, and chassis controlsystems 6, 7. The benefits of this technology includeInt J Adv Manuf Technol (2010) 51:233246automated testing, earlier testing before physical prototypevehicle build, ability to perform robustness and dynamictesting, and reduction of supplier software iterations.Machine vision systems have been used in many manufac-turing applications such as automotive 810, roboticguidance 11, and tracing soldering defects 12, 13. Theauthor also employed machine vision technology forobstacle detection in advanced driver assistant systems14, 15. However, no research has been reported using amachine vision system for design validation testing.Validation testing in the design stage is very much differentfrom testing in manufacturing. Firstly, design validationtesting requires diverse test cases covering a large numberof, rather than a restricted, set to prove proper design. Theonly way to generate the test cases when the car is in theearly development phases is using model-based testingtechniques, which simulate vehicle-operating conditions inreal time. Secondly, design validation testing requiresiterative and repeated tests for robustness evaluation,although it does not require a high volume of parts to betested. Thirdly, design validation testing needs frequentadaptation of the testing system for different types of carsor for different development stages of the same car. Onenovelty of this paper is the integration of the machinevision and HIL techniques for complex design validationtesting. In addition, the paper proposes a novel pseudo-random concept for generating three voltage transientwaveforms, which allows the testing to mimic the randomprocess as seen in real cases, and also enables the testing tobe regenerated for further investigations. Furthermore, acommon approach to mimic the operation of the touchscreen by a human is by using robot arms. In this design, acrafty resistance simulation approach replaces the robotarms to achieve the goal. The approach can be completelyimplemented in software by using the HIL simulator,therefore eliminating the need of complicated mechanicaldevices such as robot arms, pneumatic/hydraulic, andsolenoid actuators.2 System configurationsThe configuration of the system developed for testing theinfotainment system is shown in Fig. 1. The system consistsof six vital elements including the unit under test, HILtester, machine vision (camera), operation of the touchscreen, transient waveform generator, and test automation.The infotainment system under test consists of a numberof modules including the radio/CD player, amplifier(AMP), navigation system, blue tooth/telephone/USB,vehicle setup, auxiliary audio interface, and climate controlfunctions. The HMI is based primarily on a 7 TFT resistivetouch screen with additional hard keys on an IntegratedInt J Adv Manuf Technol (2010) 51:233246Images (referenced to test)EthernetRS232 SerialCamera235Vision TestTriggerTestResultsControl ParametersHIL TesterResistive control of touch screenHostPCOpticalCANTouchScreenCapture DataTest AutomationscriptsTest ScriptPrecondition.test.post conditionPrecondition.test.post conditionTrigger LowVoltage testprofileRS232ICP &Remote ContClimate/Setup/InterfaceICMgatewayPrecondition.test.post conditionPrecondition.test.post conditionPrecondition.test.post.test.post condition.Precondition .test.post conditionPrecondition .test.post conditionPrecondition .test.post conditionPowerSupplyRadio/CDplayerMOSTRingOptolyseranalyzerPrecondition .test.post condition.Blue tooth/MOST AnalyzertriggerFig. 1 System configurationTransient waveformgeneratorAudio output monitoringNavigationAMPPhone/USBControl Panel (ICP) in the center console and remotecontrols on the steering wheel. Audio output is via a DSPamplifier. Communication between the modules is througha MOST optical bus carrying control, data, and audioinformation. The infotainment system is connected to therest of the vehicle via a module called ICM acting as agateway between MOST and a vehicle Controller AreaNetwork (CAN) bus. It is worth noting that the ICP and theremote controls on the steering wheel reside in the vehicleCAN bus. In addition, a MOST analyzer was connected inthe MOST ring during the testing. The MOST analyzer wascontrolled by the HIL tester via digital outputs to trigger thelogging of the MOST traces when a failure occurs.Within the testing system, the HIL tester simulates thevehicle network and dynamically provides various essentialsignals to the infotainment system under test. It also acts as acontrol center to control other devices. For example, it sendscommands via a serial port to trigger the camera and receivethe inspection results from the camera. The machine visionsystem (camera) checks the responses of the system bymonitoring the display of the touch screen such as patternsand text. The operation of the touch screen is achieved byusing a resistance simulation approach, which is imple-mented in the HIL tester. By using this approach, the testingsystem can get access to the majority of infotainmentfunctions. The transient waveform generator producesvoltage signals and powers up the infotainment system viaa programmable power supplier. The waveform generator,mimicking three voltage transient processes, is used fortesting system robustness against low voltage events. Thetest automation is running in the host computer to integrateand control all devices to form a fully automated testprocess. In addition, the host PC has been linked with themachine vision system via a TCP/IP Ethernet communica-tion. This link allows the storage of time-stamped images inthe host PC so that the behavior of the unit under test can bereviewed offline in terms of the test results. The followingsections describe the individual elements of the automatedtesting system including the HIL tester, vision-basedinspection, automated touch screen operation, transientwaveform generator, and test experiments.3 HIL testerA dSPACE simulator 16 was used to form a hardware-in-the-loop simulation test system. The HIL test systemsimulates the vehicle CAN bus to provide power modesignals to the MOST Network via the MOST gateway. Italso simulates the ICP to operate the infotainment system.Test ResultsconditionMOST236Int J Adv Manuf Technol (2010) 51:233246Fig. 2 dSPACE real-time simulatorSimulation ModelsExpansion boxSimulation of Power Mode andintegrated control panel - CANDigital signalprocessorPower supply controlSimulation of touch Screen operationand On/Off Switches -resistanceoutputsSound detection and measuringsound frequency A/D inputsSerial communications RS232Real-time simulatorStandard I/OInterfaceCANI/O RS232In addition, the HIL tester also provides RS 232 serialinterfaces to communicate with the camera and transientwaveform generator, resistance simulation to operate thetouch screen, and an A/D interface for detecting sound andmeasuring sound frequency.The dSPACE Simulator consists of simulation models andexpansion hardware as shown in Fig. 2. The expansion boxincludes one processor board DS1006 and one interfaceboard DS2211. The DSP board runs the simulation models,while the interface board provides various interface linkswith other devices, such as CAN, resistance outputs, A/Dconverters, analog/digital input and output, and RS 232serial communication to control the machine vision system.In the HIL system, simulation models are implementedin MATLAB/Simulink/Stateflows and compiled using theauto-C-code generation functions of Matlabs Real-TimeWorkshop for real-time execution.3.1 Simulation of power modeThe behavior of the components of the Infotainment systemis determined by a CAN signal known as Power mode,which indicates the operational state of the vehicle e.g.,ignition off, ignition on, engine cranking, enginerunning, etc. To test the performance of the infotainmentsystem under cranking conditions, the car under test must bein the engine-cranking state when applying crankingtransient voltages to the car. Moreover, any subsequentfunctional tests must be conducted in the engine-runningstate after the cranking. In a real car, power mode messagesare transmitted by the body ECU connected to the CAN.Since we were testing the infotainment system on a testplatform representing a real car sometimes, in order togenerate the correct power mode behavior, we utilized CANsimulation of the HIL tester to simulate the body ECU totransmit power mode messages to the MOST gateway.3.2 ICP simulationThe Integrated Control Panel of the infotainment systemprovides users with a number of hard keys for operating thesystem. The functions controlled by the ICP includeselection of the audio sources, loading and ejecting CDs,seeking up/down for radio stations and CD tracks, volumecontrols, and so on. To enable an automated testing of thesefunctions, the ICP must be controlled by the test center, thedSPACE real-time simulator.The ICP electronic control unit interfaces with a vehiclevia the vehicle CAN. Therefore, the ICP unit was simulatedby using the CAN simulation of the dSPACE simulator.The models of ICP simulation are shown in Fig. 3.3.3 Sound detectionSound detection contains two aspects i.e., detecting soundon or off and detecting the frequency (dominant) of thesound. The sound signal is sampled from the speaker end asshown in Fig. 1, and converted into digital signal by an A/Dconverter within the dSPACE simulator. The sound on/offis determined by checking the amplitude of the signal. Thefrequency of the sound is detected by the specific circuit ofthe simulator. The purpose of detecting sound frequency isto identify a sound source and active CD track. The modelis shown in Fig. 4.Int J Adv Manuf Technol (2010) 51:233246Fig. 3 Model of ICP simulation3.4 Simulation of serial communicationsThe RS232 serial communication is used to establishthe link between the HIL tester with the camera and thetransient waveform generator so that closed loop testingcan be performed. During the test, the HIL tester is thecontrol center to command the camera and the transientwaveform generator and to obtain the inspection resultsfrom them. For example, the camera needs to becommanded to select a specific image processing jobfile for specific testing. The checking results generatedby the camera need to be returned to the HIL tester.The transient waveform generator needs to be com-237manded to generate a specific cranking waveform forspecific testing. The parameters of the waveformresulting in a failure need to be returned to the HILtester so that this specific testing can be duplicated inthe later analysis stages.A simplified version of the simulation models of theRS232 serial communication is shown in Fig. 5. Atransmitted message is ended with a carriage return andhas a maximum length of 10 bytes. A received message hasa fixed length of 8 bytes. The first 3 bytes gives the resultname while the following 5 bytes indicates the resultvalues. For example, the active track number is abbreviatedas the result name ATN.238Fig. 4 Model of sound detection4 Vision-based inspection4.1 Machine vision systemThe machine vision system consists of a camera, lighting,optics, and image processing software. A Cognex In-sightcolor vision sensor 17 was selected for image acquisitionand processing, which offers a resolution of 640480 pixelsand a 32-MB flash memory. The acquisition rate of thevision sensor is 60 full frames per second. The imageacquisition is through progressive scanning. The imageprocessing software (In-sight Explorer Ver 4.2.0) provides awide library of vision tools for feature identification,verification, measurement, and testing applications. ThePatMaxTM technology for part fixturing and advancedOptical Character Recognition (OCR) tools for readingtexts 17 are available within the software. The primarysource of illumination is
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