Introduction

This article introduces the implementation methods for vehicle-level OTA automated testing, with a focus on Polelink's vehicle-level OTA automated testing solution — PAVELINK.OTABOX. The article discusses the key features, hardware and software components, and advantages of the PAVELINK.OTABOX system, providing insights into how it can be effectively used in various testing scenarios.

Vehicle-Level OTA Automated System

Currently, there are three main methods for implementing OTA automated testing systems:

1. System-Level OTA Channel Testing System

Coverage: Covers the validation of pre-flashing entry conditions, monitoring the diagnostic interaction process during flashing, detecting abnormal system flashing responses, system faults (loss of the flashed node), post-flashing time recording, version information retrieval and collection, ECU status confirmation, and various positive and negative scenarios.

This OTA automated testing system is highly flexible, with strong potential for secondary development.

Advantages: Broad coverage of testing needs, does not rely on a real vehicle environment for testing.

Disadvantages: Higher system cost, longer development cycle.

2. System-Level OTA Stress Testing System

Coverage: Covers various stress test scenarios, including user in-car trigger/mobile app trigger, scheduled installation/direct installation, same baseline version, high version downgrade, and low version upgrade.

Advantages: Can run continuously for 24 hours, does not rely on a real vehicle environment for testing.

Disadvantages: Limited coverage of testing needs, only covers stress testing scenarios.

3. Vehicle-Level OTA Stress Testing System

Coverage: Can cover all the content of the system-level OTA stress test, and has the capability to perform tests in extreme environments (from -20°C to +40°C).

Advantages: Can run continuously for 24 hours with automated operation, short implementation cycle, lower cost, strong replicability, and requires fewer testing personnel.

Disadvantages: Relies on a real vehicle environment for testing, limited coverage of testing needs, only covers stress testing scenarios.

Each of the three OTA automated testing systems mentioned above has its own advantages and characteristics. Therefore, OEMs can flexibly choose the most suitable solution based on their testing needs.

The vehicle-level OTA automated testing system introduced today is mainly suitable for the following scenarios:

• Expectation to Verify Vehicle OTA Link Stability in a Real Vehicle Environment

• Only cover stress testing scenarios: The vehicle-level OTA automated testing system can only cover stress testing scenarios due to the limitations of testing in a real vehicle environment. It cannot cover channel testing content and is suitable for 24-hour continuous stress testing.

• Lower Testing Cost and Shorter Implementation Cycle: Compared to system-level OTA testing systems, the vehicle-level OTA automated testing system has the advantages of lower cost and shorter implementation cycle, making it suitable for OEMs with lower budgets and urgent testing needs.

• Need for Mass Replication: Compared to system-level OTA testing systems, the vehicle-level OTA automated testing system has a strong advantage in replicability, making it suitable for OEMs that need to use testing systems in bulk.

• Need for Testing in Harsh Environments: Compared to system-level OTA testing systems, the vehicle-level OTA automated testing system has the capability to perform tests in extreme environments (from -20°C to +40°C), making it suitable for OEMs that need to conduct tests in harsh conditions.

PAVELINK.OTABOX Solution

Given the characteristics of vehicle-level OTA automated testing, Polelink has conducted an in-depth analysis of the OTA processes of major OEMs and launched a generalized vehicle-level OTA automated testing solution — PAVELINK.OTABOX. Based on this, customized development is carried out for different OTA processes to achieve automated testing at the vehicle level. Below is an introduction to the overall structure of PAVELINK.OTABOX.

Hardware Layer: The PAVELINK.OTABOX testing solution includes an outdoor power supply and an OTA testing box. The outdoor power supply powers the OTA testing box, and it is mainly configured for fuel vehicles and hybrid vehicles. For electric vehicles with automatic recharging capabilities, the vehicle's 12V battery can be considered to power the OTA testing box. The OTA testing box, as the core tool of the solution, monitors and simulates bus messages through bus simulation and collection interface cards. An industrial computer configures and executes the test project, and the testing interface connects to the vehicle.

Software Layer: The PAVELINK.OTABOX solution consists of three main parts:

  1. Logic Definition Module (Test Center): Responsible for visual case construction, test task arrangement, and test task execution. The specific execution of logic is also controlled by the Test Center.

  2. Logic Forwarding Module (Test Agent): Serves as the logic forwarding port, responsible for forwarding logic execution requests issued by the Test Center, including project calls, automatic operation and stopping of CANoe test projects, OTA Server service calls, sending control instructions to the UE, and collecting execution results.

  3. Logic Execution Module: Used to execute test projects, OTA server calls, and UI/UE identification and collection.

•   CANoe Project: Implements basic functions, including message simulation, power control, signal simulation, and BOB control.

•   UI/UE Project: The operation of confirming the upgrade conditions through the touch screen is realized by ADB commands. ADB commands rely on the car machine to open ADB permissions, and the click screen commands are encapsulated in the UE.exe module.

•   OTA Server Call: Implements control of the OTA Server, including task pushing and execution record query.

In the entire solution, the core member for test execution is the CANoe software, which carries out the execution of the test project and the simulation of the test environment, supplemented by the test cabinet hardware and UI/UE project for test execution operations. The core member for test management is the Test Center software, which can manage multiple testing systems through a single management software, supplemented by the CANoe Agent software, enabling control over test project startup and shutdown as well as test report management.

Next, we will introduce the PAVELINK.OTABOX case:

The PAVELINK.OTABOX case is a portable testing system tailored by Polelink to meet customer needs for vehicle-level OTA automated testing. The case integrates a small industrial computer, bus interface cards, and power management modules. While meeting customer testing requirements, it minimizes the size and weight of the testing system, facilitating the movement or placement of the testing system in a real vehicle environment, significantly enhancing the flexibility of the testing system.

Conclusion

In summary, the entire vehicle-level OTA automated testing solution is based on Polelink's PAVELINK.OTABOX testing case as the hardware foundation, CANoe software as the core testing execution tool, and Polelink's self-developed Test Center software as the core testing management software, supplemented by the CANoe Agent software, providing the capability for vehicle-level OTA automated testing. The solution supports mass production at low costs within a short time frame.

Through the 24-hour automated operation of PAVELINK.OTABOX, the test sample size can be increased, and download and installation data can be captured in real-time during the test, avoiding the uncontrollability of manual operations. Compared to manual testing, using PAVELINK.OTABOX for automated testing can at least double the efficiency, reduce human resource costs by at least 50%, and offer higher reliability and stability.

In recent years, Polelink has collaborated with several major Chinese domestic OEMs to complete vehicle-level PAVELINK.OTABOX automated testing system development projects, accumulating extensive practical experience. Through continuous iterations, a series of optimizations and improvements have been made. We welcome interested colleagues to communicate and collaborate with us for mutual progress.