End-to-End Cloud-to-Device Integrated OTA HIL Testing Solution
With the rapid development of Intelligent Internet Connected Vehicles, OTA (Over-the-Air) technology has become the core means of vehicle software upgrade. In order to meet the increasingly stringent regulatory requirements and technical challenges, TOSUN has launched an integrated OTA HIL test system based on the ISO 24089 and GB 44496 standards, which realizes compliance, high efficiency, and automated verification of the whole OTA process.
One,Background and Regulatory Basis for OTA Testing
Major international and domestic regulations such as UNECE R156, ISO 24089, and China's mandatory national standard GB 44496 together build a standardization framework for software upgrades of smart connected vehicles.GB 44496, as China's first mandatory national standard for OTAs, clearly puts forward key technical requirements such as end-to-end encryption, digital signatures, security isolation, and recovery from power outages, which are necessary conditions for the listing of vehicles on the market. It is a necessary condition for the vehicle to be listed on the market.

Two,TOSUN OTA HIL test content
TOSUN OTA test system provides full-stack test capability from parts to the whole vehicle, covering the following seven major test types:
Regulatory compliance testing:
Verify compliance with ISO 24089, GB 44496 and other standards, including mandatory clauses such as vehicle condition testing before upgrade
OTA functionality testing:
Including upgrade package download, multi-ECU brushing and writing, installation progress reporting and user interruption recovery capabilities and other basic OTA link functions, covering both positive upgrade and upgrade exception scenarios.
OTA Performance Test:
Evaluates resource utilization and timeliness, including gateway load, CAN FD bus utilization, single ECU refresh and write time, and multi-ECU parallel upgrade performance.
OTA Safety Testing:
Test threat scenarios such as man-in-the-middle attacks, replay attacks, installation package tampering, etc. according to ISO 21434 and GB 44495.
OTA Reliability Testing:
Simulate extreme working conditions, such as continuous recovery from multiple power failures, continuous multi-ECU brushing, high and low voltage/different ECU interaction testing, power fluctuations and weak/no network testing.
OTA Failure Test:
Construct a multi-dimensional test matrix, including network interruption test during download, power interruption test during brush-write process, brake failure test during brush-write process, etc.
User experience testing:
Quantitatively evaluate the clarity of the upgrade prompts, the accuracy of the progress estimation and the synchronization of multi-modal interactions (voice/screen/APP), and collect and provide feedback to optimize the process.
Three,System architecture: full coverage from components to real vehicles
TSMaster UDS diagnostic function not only supports CAN/CANFD, LIN, but also supports Ethernet DoIP diagnostic brushing function. TSMaster can complete the diagnostic process development with less code or even zero code, which can quickly open up the diagnostic link and technical realization of R&D, production line and after-sales. The main functions of TSMaster's DoIP zero-code development are as follows.
OTA HIL System Hardware Architecture
TOSUN provides a variety of OTA HIL test equipment programs to adapt to different test levels:
1. Single-node BT protocol conformance test program
It consists of standard cabinet, bus protocol conformance test board, programmable power supply and TSMaster, which realizes UDS/DoIP protocol brush-write protocol conformance verification and fault injection test of ECU.

2. Component-level OTA test program
It consists of a standard cabinet, a shielding box and a TSMaster uplink, which realizes the full-function and full EEA architecture of the ECU for the verification of the OTA writing process and the fault simulation test.

3. System-level OTA test program
Integrated HIL test cabinet, shielding box, LabCar rack, host computer, wireless network signal control, multi-domain controller simulation environment and programmable power supply and other equipment, to complete the timing synchronization and network load verification of cross-ECU cooperative upgrade.

4. Real vehicle level OTA test program
Through the portable bus recorder and the cloud task management system linkage, to realize the OTA scene replication and regression testing before batch push.

OTA HIL system software architecture
The software architecture of OTA HIL is built based on TSMaster virtual instrument software platform, which provides full-stack testing capability from the bottom hardware control to the cloud collaboration, and includes a three-layer OTA system development and testing platform with user interaction layer, system application layer, and virtual hardware simulation layer.

IV. OTA HIL test application scenarios
Performance Testing:Monitors bus load, Flash write rate, and multi-ECU parallel upgrade capability;
Failure testing:Simulate scenarios such as power interruptions, network flashing, and malicious attacks;
Live car monitoring:Synchronized acquisition of signals such as electrical status, network communication, and HMI response;
Multi-vehicle testing:Support cluster concurrent upgrades to verify system scalability and robustness;
……

Contact Us
For more automotive test solutions, please contact us by private message or email, TOSUN will be happy to provide you with customized solutions.
Official website:www.tosunai.com
Mailbox:sales@tosunai.cn


