Research on Standardized Fault Injection Technology for Multiple Failure Mode of Electronic Control Systems

The electronic control system (ECS) of high-pressure common rail (HPCR) diesel engines serves as the powertrain's central controller and has become increasingly complex, with a growing number of control components, higher integration levels, and highly compact packaging. These characteristics impose significant challenges on the accuracy, safety, and effectiveness of fault injection (FI). To address the lack of standardized and systematic FI techniques, this study proposes a generalized multi-type FI methodology and develops an integrated FI platform for HPCR diesel engine ECSs. By analyzing typical ECS fault modes, four complementary FI strategies are introduced: hardware-in-the-loop (HIL)-based FI, physical hardware-level FI, health-index-driven FI, and expert-knowledge-guided FI. Based on these strategies, an integrated FI platform is constructed, incorporating HIL hardware, control management software, a health-index module, and an expert knowledge base. The case verification shows that this methodology and platform can effectively recreate various fault characteristics, enhancing the controllability and effectiveness of fault injection. It provides systematic technical support for the verifying the testability of the high-pressure common rail diesel engine electronic control system, thereby improving product design reliability.