Test of Automotive Boards

This thesis work analyzes the testing techniques for automotive ECUs in the End of Line phase. The SW architecture used today and the future developments based on the AUTOSAR standard are therefore analyzed by studying their features, advantages and disadvantages. ECU testing methods with different SWs are then compared, by analyzing their characteristics, complexity and potential. This work ends with the analysis of an ECU based on AUTOSAR, and the study and implementation of test modules. The document is structured in chapters: 1. The introduction of the thesis work. 2. The introduction of Magneti Marelli S.p.A. history, and the description of the main company business lines. 3. Description of powertrain in automotive field, and report of Magneti Marelli Powertrain business line products. 4. Introduction on Battery Electric Vehicles (BEVs) and Hybrid Electric Vehicles (HEVs). It is explained more in detail the Battery Management System (BMS) and the complexity of the electronics used to control the charge/discharge of the batteries. 5. Description of an ECU, its main functions, and the reasons for which the device must not fail during its work. Errors in ECUs are not allowed and they should be avoided by testing the whole device before sending it to the customer. The main methods for ECU wire communication are also described by underlining the main advantages and disadvantages. Dexcription of the functions and the signals that have to be tested are analyzed in order to be sure that the device works as intended. Testing involves the stimulation of specific hardware pins in order to verify their correct behavior. Often it becomes necessary to recreate the working conditions of the ECU to be able to test its functioning. 6. The main generalities of the standard are presented in detail, up to the description of the layered architecture that provides it, highlighting the key points. A focus is done on the vehicle diagnostic features that the AUTOSAR standard offers, underlying the main characteristics and functions of the Diagnostics Communication Manager (DCM). This module can read/write ECU errors, and it also supports the diagnostic protocols UDS and OBD II. 7. Description of the architecture of an ECU in the host company portfolio. Different SW architectures are presented. Testing techniques are analyzed too. The UDS protocol is then described. 8. Description of the development of test automation for the automotive system model. It is also explained the safety standard as proof that substantial safety measures has been taken for a certain product. There is also a standard ISO 26262 that ensure functional safety to ”absence of unreasonable risk due to hazards caused by malfunctioning behavior”, and the different safety levels Automotive Safety Integrity Level (ASIL) are explained in order to distinguish different safety protection levels among. 9. Descriptions of the steps through which the bare board is transformed into a final product passing through Front-End and Back-End phases. 10. Summary of the work done in Magneti Marelli by starting from the description of the programs and tools used, then showing some examples of function calls to test hardware pins. 11. Personal reflections and comments on the work done. Motivations and the reasons that led the company to make the choice to write test programs for ECUs. The goals set and the results obtained are compared. Possible further research developments are then analyzed.