Pi Innovo’s approach to OpenECU DV testing starts in the requirements phase of the ECU development with architectural decisions and the authoring of a system requirements and a test strategy. The systems requirement defines what system level tests are appropriate for the development and the test strategy describes the basic functional/parametric tests and breaks validation tests into pre-DV, DV, PV, and production phases. As development progresses, additional test documentation is created such as a DV Plan, a Production Test Requirement, and a variety of test scripts.
Once the initial specifications are ready, DV/PV tests are run within Pi Innovo’s facility when possible. When this is not feasible (due to large capital constraints such as EMC chambers or mechanical fixtures), Pi Innovo works with local test laboratories to perform the tests. Pi Innovo’s Plymouth office is centrally located to both EMC & environmental test laboratories. TUV Sud America, an EMC test provider that Pi Innovo regularly uses, is located less than one mile away from Pi Innovo’s office. Outsourced mechanical tests are similarly close, with NTS Detroit being less than a thirty-minute drive from the Pi Innovo office.
For new ECUs with novel circuitry or mechanical concepts, pre -DV is used to refine the design prior to a full DV test battery. Pre-DV tests target higher risk design components to address critical flaws early in the design cycle. For example, if the OpenECU project has a new enclosure concept, pre-DV may target vibration, mechanical shock, and drop tests. Pre-DV testing provides a head start on the development of the test infrastructure including vehicle simulators/load boards, harnesses, and functional test scripts. Additionally, pre-DV helps refine product documentation as Pi Innovo engineers must document interfaces and load profiles internally and for outsourced test facilities.
After pre-DV issues are resolved, an OpenECU is ready for DV. The DV tests are designed to verify that the OpenECU meets the functional and environmental requirements that were described in the systems requirements document. (INSERT LINK to 15). Some common types of DV tests include:
- EMC, Emissions (CISPR25)
- EMC, Immunity (ISO 11452)
- Electrical Tests (ISO 16750)
- Mechanical Tests (ISO 16750)
The tests types ab ove represent only a handful of tests that Pi Innovo runs for OpenECU controllers. For a complete list, DVP&Rs can be provided on request for any OpenECU product. If you have custom requirements for testing, Pi Innovo can also run additional tests to provide a tailored DVP&R that meets your requirements. We have experience with multiple OEM specific validation standards including (but not limited to):
GMW 3097, GMW3172, BMW GS 95002, MB 10284, FCA CS.00054, JLR-EMC-CP, and VW 80000
Pi Innovo can also provide support for system integration & validation testing or dynamometer testing through our systems engineering group.
PV testing is typically performed on ECUs that are designed for series production vehicles. PV tests verify that the production processes used by the contract manufacturer builds ECUs correctly. Depending on what was tested in DV, PV testing may be tailored to reduce effort & cost where the processes were sufficiently covered by the earlier DV tests. PV data proves the effectiveness of a variety of production processes including PCB assembly, in-circuit testing, and end of line testing.