Adapting a 3D Printer as a Robot for Testing Electronic Control Units in Automotive Context

Abstract: As a result of a multitude of safety- and comfort-functions, most modern automobiles contain various electronic control units. The automobiles’ passengers can control several of those functions not only by activating mechanical switches, but also by using sensory control elements. Sensory control elements mostly use capacitive effects induced by contact to determine whether a function should be executed. Aforementioned contacts might be in the form of touches or slides. During the development of sensory control elements, it is desirable to test the devices as early and as often as possible to ensure a continual adaption of sensor calibration and evaluation. The significance of such tests is provided by repeating tests at equal positions with comparable velocities and applied forces. Therefore, robots are already used to perform such tests. The operational availability of the previously mentioned robots has been proven to be too short, which is why not all developers are provided with sufficient test capacities. To approach this problem, the development of a duplicatable robot system with respect to a constrained budget has been realized. Due to the high costs of complete robot systems, this thesis contains an experimental approach by remodeling a 3D printer. An adequate system has been developed by remodeling mechanical-, hardware- and firmware aspects of the original system. Furthermore, a user software has been programmed. Essential aspects of the remodeling include construction designs for mechanical changes, hardware- and firmware integration of a force sensor, implementing a force-dependent stop of movements and communication with the user software. Essential aspects for the user software include the design of a GUI as an interface between the user and the system, the automatic generation of coordinated movements and communications with the robot. Further development should include an improved validation of force measurements, a more accurate force-dependent stop, more accurate determination of reference points and the optimization of the built-in working area. Additionally, the current force sensor only measures forces in one axis. It is suggested to replace it with a three-axis sensor.

Keywords: Robotics Application, Testing, Automated Testing

DOI: 10.54941/ahfe1004406

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