2011 3rd International Conference on Advanced Computer Control (ICACC 2011)

Functional Testing System Based on LabVIEW for Gas-fueled Automobile Engine

ECU

Huizong Feng Fenglin Liu,Yang Xu

Office of Academic Affairs,ChongQing University of Posts Automation College,ChongQing University of Posts and
and Telecommunications, ChongQing ,400065, China Telecommunications, ChongQing ,400065, China
e- mail: fenghz@cqupt. edu.cn e- mail:[email protected]@163. com

Abstract-The functional testing system for gas-fueled auto­ enhances the combustion rate of the flammable gas and
mobile engine ECU (Electronic Control Unit) is designed based reduces vehicle exhaust emissions.
on LabVIEW (Laboratory Virtual Instrument Engineering Taking into account of the characters of the gas-fueled
Workbench). The system hardware is composed of engine automobile engine ECU under test,this system mainly tests
ECU,data acquisition(DAQ) boards,a personal computer and the following four functions: ignition control, deceleration
some external circuits.This system mainly tests the three
air feed cut-off solenoid valve relay control,stepper motor
functions of ignition control and deceleration air feed cut-off
control.
solenoid valve relay control,stepper motor control. By the
contrast of the system's results and the calibration data, it can B. Overall Structure of The Testing System
be validated that whether the test system is accurate and
Based on PCI bus technology, the functional testing
reliable or not .
system mainly includes industrial PC, gas-fueled automobile
engine ECU, data acquisition board cards, LabVIEW
Keywords-Lab VIEW; Virtual Instrument;Electronic Control
software, driver software, signal junction boxes, electric
Unit ;Data Acquisition; Functional Testing System
power supply as well as some external circuits. The overall
structure of the system is showed in figure 1.
I.INTRODUCTION ECU iuput signal Ii data
Data lVrite
. . . r
In recent years, the number of gas-fueled automobiles has
Control Object �
ECU
acqUlStltOn
ECU output signal �-�I Device
d'
nver Readdala �
PC
L abVIEW
gradually increased in China. Targeted at saving energy,
reducing emissions , protecting the environment and
f � bo
L-__---' ---':--':- I
ards
I
Figure 1. system overall structure
Improving security, people are considering these issues more
and more. Hence more rigorous functional testing and
Through using the computer simulation technology with
inspection are needed for the engine ECU products in order
data acquisition installment and the LabVIEW programming
to solve these problems.
control, it can generate the input signals of engine ECU
LabVlEW is a graphical programming environment
controllor. At the same time, it is needed to gather and
based on the concept of data flow programming. This
analyze and display the output signals'results of ECU
programming paradigm has been widely used for data
actuator and compare them with calibration data to see
acquisition and instrument control. There are three important
whether it meets the anticipated requirements or not.
components involved in test and measurement
applications,namely data acquisition,data analysis and data C. System Hardware Structure
visualization. LabVlEW can be used for creating flexible and The hardware architecture of the testing system is
scalable test, measurement,and control applications, which showed in figure 2.
covers these vital components. PC

rl��
Host
Based on the analysis of the work principle of the gas­

'
fueled automobile engine ECU ,we can use the software of
PCI PCI �
P l
LabVlEW, PXI chassis, data acquisition boards to develop a 7S13R 6514 6723

functional testing system for gas-fueled vehicle engine PWM Digital Voltage

J
Signal 110 Output
ECU.ln the testing system, it can display the output results in
various forms in the front panel of LabVIEW, and it can
complete the signals' data acquisition, measurement ,analysis, ,'- ECU ""
Engme>-
I I
processing, recording and saving in the programming block Figure 2. system hardware architecture
diagram of LabVlEW.
NI PCI-7813R board belongs to R Series Multifunction
II.FuNCTIONAL TESTING SYSTEM ARCHITECTURE
RIO( Reconfigurable I/O ) which gives you the ability to

A. Purpose of The Testing System

define your own custom measurement hardware circuitry
using reconfigurable field- programmable gate array (FPGA)
It's known that Engine ECU is the electronic control
chips and NI LabVIEW graphical development tools. It
module which is responsible for controlling the engine. Its
requires the LabVlEW FPGA Module 7.1 or later and NI­
main application is to carry on the closed-loop control for the
RIO 1.3 or later driver software. In this system, pin digital
engine's gas-fueled system and ignition system, thus

978-1-4244-8810-0111/$26.00 ©2011 IEEE 357

 2011 3rd International Conference on Advanced Computer Control (ICACC 2011)

1/00 and digital I/OI are selected to provide channels for the Front panel of the main program for the functional testing
crankshaft rotational speed pulse signal (CRANK) and the systems using LabVIEW is showed in Figure 4.The data in
camshaft position pulse signal (CAM) respectively as well as the upper part of LabVIEW front panel which are the ECU
pin digital 110 2 to digital 110 7 for first cylinder's ignition input signals ,can be adjusted. The following part of front
pulse signals (IGN) to the sixth cylinder's ones in turn. panel can display the ECU out ut si nals.
NI PCI-6723 board which belongs to high-speed voltage Functional Testing SJste. for Gas-fueled
AutOilobile Engine ECU 1011::111::10 2010-11-'10

output devices ,has 32 analog I/O lines . Use these modules

in a variety of applications, including stimulus-
response, power supply control, high-speed, deterministic
control, and sensor/signal simulation. Before using the OAQ
board,it needs to set up NI-OAQmx driver software to create
the channels of data acquisition . Here,we select analog
1/00- 1/07 line for ECU to provide the channels of analog
voltage output signals, such as gas pressure signal(GPS), gas
temperature signal(GTS), gas tank pressure signal(TP),intake
manifold absolute pressure signal(MAP), intake manifold air
temperature signal(MAT),coolant temperature signal Figure 4. LabVIEW front panel of the main program
(CLT)and electronic throttle position signal(TPS) and other
analoy signals.
III.FuNCTIONAL TEST FOR IGNITION CONTROL
NI PCI-6514 has industrial 64-channel isolated digital
I/O interfaces for PCI systems,which canbe used for Ignition signal (IGN) is one of the most important control
general-purpose data acquisition applications as well as signals for engine ECU. It is measured from the ignition
industrial control and automated manufacturing test. With advance angle. From the moment when the engine starts to
high current drive and isolation, you can connect the digital ignite to the moment the piston reaches the compression
I/O directly to a wide array of 24 V electronic devices, ignition top dead center (TOC), in this period ,the angle
sensors, and actuators. NI 651x devices take advantage of which the crankshaft(CRANK) turns is called ignition
NI-OAQmx software, which includes technology to speed up advance angle.
application development. In the system,the card controls
A. Test Principle
switch signals, such as deceleration air shut-off solenoid
valve relay signals and stepper motor status signals. Physical acquisition, the ignition signal is described as: 0
� 5V digital pulse signal.The engine ECU has six ignition
D. System Software Structure cylinder. Coolant temperature signal, the engine intake
The testing system uses NI LabVIEW7. 0 platform to manifold absolute pressure signal, electronic throttle position
design software programs , because LabVIEW is a graphical signal and other analog signals are the the revision signals
programming language that can be a very intuitive way to for ECU ignition advance angle . And crankshaft speed signal
create human-machine interface front panel and block (CRANK) and the camshaft position signal (CAM) are the
diagram. To complete the data acquisition and signal main signals for ECU ignition advance angle. Among them,
generation,it needs to install OAQmx module driver, FPGA the camshaft position sensor of ECU provides the first
module driver, and device driver.After driver installation is cylinder's compression TOC signal. Crankshaft consists of
successful, you can use the programming function of three gears. Crankshaft rotational speed signal and the
OAQrnx module and the LabVIEW FPGA module which are camshaft position signal and the ignition signal with the
responsible for continuously reading and writting data in the phase relationship is showed in Figure 5. Ignition time is
entire testing process. The software structure of the testing denoted by 6t ,and the crankshaft speed cycle is denoted by
system is showed in Fiaure 3 . T. According to the phase relationship showed in Figure 5 ,it
,&���--------�
can calculate the advance angle of each cylinder(IGN) by the
formula:
I gnition Avance Angle =6t/T * 120°
120·

IGN
,
I�nition advance an�le

Figure 5. phase relationship between the signals of

CRANK,CAM and IGN

B. Ignition Test Realization

I)Revision Signals
Figure 3. the testing system software structure

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 2011 3rd International Conference on Advanced Computer Control (lCACC 2011)

Coolant temperature signal, intake manifold absolute 250 7.0 5.4 3.7 3.6 2.3 2. 0 0.8 9.7
pressure signal, analog signals, electronic throttle position 2 2 2 " " " "
signal and other analog signals are the the revision signals 500 8.0 6.1 4.0 3.4 2. 9 3. 1 1.4 0.2
for ECU ignition advance angle .First, these signals need to By companng actual test data obtamed WIth the
be converted into the corresponding voltage value. Selecting calibration data, in front panel, it can seen that the absolute
the pins aoO-7 of PCI-6723 board to provide eight physical error is less than 0.3 degree. This is mainly caused by the
channels for these analog voltage outputs,then use the following two reasons:
LabVIEW OAQmx module and data acquisition interface to 1)First, ignition advance angle = main parameters +
write these analog voltage signals to the ECU as its control revision parameters. The way in which revision parameters
signal. impact on ignition advance angle, is mainly by affecting the
2) Main Signals additional reference factors that electronic control algorithm
According to the phase relationship showed in Figure 5, requires.
it needs to design FPGA subroutine . The pins 0100-1 of 2)Second,some of the data errors which are
PCI-78l3R board are select to provide channels to generate inevitable,are caused by the system hardware. This part of
square waveforms for the crankshaft speed pulse signal and the errors are caused mainly by the accuracy of the
camshaft position pulse signal.And the pins DI02-7 provide hardware instruments themselves.
physical channels for six-cylinder ignition signal to gain their
data acquisition results. IV.FUNCTIONAL TEST FOR THE CONTROL OF DECELE-
Test Results and Analysis RA nON AIR FEED CUT-OFF SOLENOID VALVE RELAY
After running the main program and providing power to
The deceleration air feed cut-off solenoid valve relay
the ECU to make it work, the waveforms of the crankshaft
(OFCO) is a device which is installed in front of the fuel
speed signal and the first cylinder ignition signal measured
distribution valve. Its function is to cut off the supply of gas
by the are showed in 6. at the high speed working condition when the car suddenly
slows down, so as to achieve the purpose of saving gas.
While working the deceleration air shut-off solenoid valve
relay is switched on. Otherwise it is switched off in the case
of sudden deceleration.

A. Test Principle

The outpus of deceleration air feed cut-off solenoid valve

Figure 6. real waveforms of crank signal and first cylinder if,rnition signal relay are digital signals (0 � 12V). It is valid when the signal
is in low level. So its state values is "F"( High Level) if the
At room temperature, through changing the two signal voltage is more than 5V and less than 12V,or
important parameters - the crankshaft rotational speed signal "T"(Low Level) if the signal voltage is less than 5V.
and intake manifold absolute pressure signal both of which According to the principles of electronic control system, the
mainly affect the ignition signals ,it can obtain the ignition state of deceleration air feed cut-off solenoid valve relay is
advance angles.Parts of the data are showed in Table 1 . mainly affected by ankshaft rotational speed, intake manifold
pressure and electronic throttle position.
TABLE! TEST DATA OF IGNITION ADVANCE ANGLE
The test methods are as follows :
1)If other conditions keeps on being invariable and the

�
value of electronic throttle position signal(TPS) is more than
2 3 4 f � ( 2%, the relay is switched on. Otherwise it is switched off.
0 0 0 0 0 0 0 0 2) If other conditions keeps on being invariable and the
value of intake manifold pressure(MAP) is more than
33 kPa,
7 2 2 1 1 I 1 1 1 the relay is switched on. Otherwise it is switched off.
50 1.0 0.5 9.7 9 9.4 9.2 9.2 9.2 3) If other conditions keeps on being invariable and the
1 2 2 1 1 1 1 1 1 value of crankshaft rotational speed (CRANK ) is less than
000 2.3 1.4 9. 4 8.6 7.5 7.4 7.5 6.7 1200rpm, the relay is switched on. Otherwise it is switched
1 2 2 2 1 1 1 1 off.
250 3.0 2. 1 l. 6 0.5 9.7 8.7 8.1 6.2
B. Test Realization
1 2 2 2 " 1 1
500 4.2 3.5 3.0 2 1.4 0.5 9. 0 7.6 First, linel in portl of PCI-6514 board is chosen to
provide the physical channel for the signal of deceleration
1 2 2 2 " " 1
750 4.9 4.3 4.2 2.8 l. 6 0.8 0.2 died the solenoid valve relay. Then software program of data
7.9
acquisition is designed with OAQmx module to read and
2 2 2 2 1
display the booI state values of the deceleration air shut-off
000 6.1 4.6 3.4 2.3 1.4 0.8 0.1 8.9
solenoid valve relay signals. The data acquisition program
2 2 2 2 1
with OAQmx is showed in Figure 7.

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 2011 3rd International Conference on Advanced Computer Control (lCACC 2011)

four loops of stepper motor be switched on.The stepper

motor is driven to tum the appropriate steps to regulate the
amount of bypass air,so as to make the stepper motor to run
stablely with the idle speed control in the range of the target
speed.
2)Test methods are as follows:
a) Power-on detection. Tum off the power for ECU, and
run the test system.Then tum on the ECU power ,and record
how many steps the stepper motor has runned.
Figure 7. the data acquisition program with DAQmx b) Running test. Change the crankshaft rotational speed
and the intake manifold pressure,then record how many steps
the stepper motor has runned.
C. Test Results and Analysis
3)Test realization are as follows:
The values of crankshaft speed (CRANK), intake We can select line2-5 in port I of PCI-6514 board to
manifold absolute pressure (MAP),and electronic throttle provide four digital I /0 channels for A,8,C and D four
position signal (TPS),are changed to see the bool value of phases signals. And software program with DAQrnx module
deceleration air feed cut-off solenoid valve relay signal is designed to read these digital signals.In addition, the data
(DFCO) is switched on or switched off. The test results are type of these digital signals is one-dimensional bool
as follows: array.The bool data is "T"( High Level) if the signal voltage
is more than 5V,or "F "(Low Level) if the signal voltage is
TABLE I! THE RUSULTS OF DECELERATION AIR SHUT-OFF
SOLENOID VALVE RELAY
less than 5V.

CRANK RPM<:101611'm B. Test Results and Analysis

MAP RPM;,120Orpm 1016<RPM<1200
MAP2:25kp(0.78V
TPS MAP<:21kp(0.57V) 21<MAP<25
)
After ECU is power-on , the stepper motor runs forward
TPS<:2%(0.09V) 2%<TPS<6%
TPS;,6%(0.28V) or runs reversely. Then it can change the crankshaft
DFCO rotational speed to gain new values of forward steps and
Be switched off (high Be switched on
Be at cushion state
level,9.92V) (low level, l.64V) backward ones.

150

I )CRANK2': 1200rpm&MAP'S21kp(0.57V)&TPS'S2%(0. 140

09V): DFCO is switched off (high level, 9. 92V).
130
2)1016<CRANK<1200&21<MAP<25&2%<TPS<6%:
120
DFCO is at the cushion state.
:;;
'"

3)CRANK'S1016rpm&MAP2':25kp(0. 78V)&TPS2':6%(0. '"

110
;:
28V):DFCO is switched on (low level, 1.64V). 100
According to the principles and methods mentioned in 90
last chapter, it is seen that the test results can meet the test
80
requirements .
70

V. FUN CTIONAL TEST FOR STEPPER MOTOR CONTROL J'tA.p (kPa) 20 500 CRANK (r/min)
igure 8. the gragh of stepper motor control
Stepper motor which is connected to the main nozzle of
the intake manifold, is responsible for controlling the amount
By observing the measured data and comparing the
of gas inflow into the engine cylinder.On different working
measured data with the calibration data,the error is less than
conditions, the corresponding angle the stepper motor turns
5 steps. And the results can meet the design requirements.
is also different. When ECU is power-on, the stepper motor
control signals are resetted. While the system is running, the VI. CONCLUSIONS
signals control the amount of gas inflow under different
crankshaft rotational speed. Along with the development of automobile industry,
people are paying more and more attention to the issues of
A. Test Principle and Realization ECU high performance and high security.Moreover,the
Stepper motor control signals are on the working way of functional testing for engine ECU is one of the important
four-phase four-beaUt includes A,8,C and D four phases means to ensure high safety and efficient operation of
signals which are all digital signals( 0 � 12V). automobile engine. In this testing system, the user can add
I )Stepper motor control process is as follows: the corresponding control logic signal and function modules,
In ECU ROM, it stores the target idle speed data which so the testing system has certainn scalability and flexibility .
are corresponded to the coolant temperature and the air­ with the use of virtual instruments to set up the testing
conditioning working status. When ECU judges the engine is system structure, the hardware equipments is modular, and
alreary in idle working condition according to the electronic graphical programming LabVIEW is intuitive,easy and fast.
throttle position sensor and the vehicle speed signal,it makes Compared with the traditional testing methods, the functional
the control pulse output by a certain sequence and lets the test system has the following characteristics: the general-

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 2011 3rd International Conference on Advanced Computer Control (ICACC 2011)

purpose hardware platform, low cost, shorten software [5] Chien-Lung Cheng , Vi-Hung Lan , "Automatic testing system based
on LabVIEW for DC motor of portable washing machine",IEEE, 489-
development cycle as well as enhanced degree of system
493,2008.
integration.
[6] Asan Gani,M.JE Salami, "A LabVIEW based data dcquisition
system for vibration monitoring and analysis", Student Conference on
ACKNOWLEDGMENT
Research and Development Proceedings, Shah Alam, Malaysia.62-65,
This work is supported by Nuclear High Base Significant 2002.
Subject of China under Grant N0.2009ZX01038-002-002-2 Huizong Feng received the PhD degree in Mechanical
and Natural Science Foundation of Chongqing under Grant Engineering from Chongqing University in 2004.He is a
NO. CSTC,2008BA2043. professor in Chongqing University of Posts and
Telecommuni- cations. His research interests include System
simulation, Automation control, and intelligent vehicle.
REFERENCES
Fenglin Liu is studying in Chongqing University of
[1] 80 Song,Zhongneng Zhang, "Feasibility analysis on software test Posts and Telecommunications for Master Degree.Her major
automation test based on system functional test. Computer application is Detection Technology and Automatic Equipment.Her re­
and software , 22 (12),31-33,2005.
searches include automobile electronic and engine ECU
[2] Zhenshan Lei, LabVIEW Express operative technology course,
functional testing system.
Beijing:Chinese Railroad Publishing house,2004.
Yang Xu is studying in Chongqing University for
[3] Guoqiang Fang, Automobile electronic control system ,Beijing:
Industry publishing house,200S.
PhD.He is an associate professor at Automation
College,Chongqing University of Posts and
[4] Yinping Ma, LiangLiang Xu,Ru Peng, "Analyze and design for data
acquisition system based on LabVIEW ", Application of electronic Telecommunications. His research interests include image
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driver system.

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