Welcome

Developing Testing Technologies

for Remanufacturing Automotive for Remanufacturing Automotive
Systems Communicating via CAN Bus
P f R lf St i hil Prof.RolfSteinhilper
Dr.StefanFreiberger
Matthias Albrecht MatthiasAlbrecht
JosefKufl
ConstantinBrckner
November13,2009
BayreuthUniversity
Germany
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and Remanufacturing
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Table of Contents
Introduction
TrendTowardsMechatronics andElectronics
CANReman ResearchProject
Example:ElectroHydraulicPowerSteering(EHPS)
Conclusion
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and Remanufacturing
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City of Bayreuth
Europe
Population:75,000
Worldrenowned for
i h d i l
Germany
RichardWagnerFestival
Halfway between
Munich &Berlin
Bayreuth
Bayreuth
2
Munich
Images: maps.google.de
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Bayreuth University
Since 1975
9200 Students
6 Faculties
Mathematics, Physics, Informatics
Biology, Chemistry und Geology
Law and Economics
Linguistics and Literature
Cultural Studies
Applied Sciences (since 1998)
3
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Chair Manufacturing and Remanufacturing Technology
Assembly
Design for Disassembly
Remanufacturing
Plant Layout
O ti i ti
Disassembly
y
Optimization
Cleaning
Reconditioning
Testing
Cleaning Technologies
Testing
Cleaning Technologies
for Turbo Chargers
and Diesel Particle Filters
4
CNC Surface Brushing
Testing and Diagnosis Technologies
for Automotive Mechatronics
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and Remanufacturing
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Table of Contents
Introduction
TrendTowardsMechatronics andElectronics
CANReman ResearchProject
Example:ElectroHydraulicPowerSteering(EHPS)
Conclusion
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and Remanufacturing
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Remanufacturing Products and Parts Now and in the Future
Trend towards
Mechatronics/
Electronics
6
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Remanufacturing Process Steps Changes for Mechatronics
Important additional Step for Remanufacturing
of Car Mechatronic Systems
Quality Assurance
of Car Mechatronic Systems
Quality Assurance
1. Initial Diagnosis of the System
2. Complete Disassembly of the Product
3. Thorough Cleaning of all Parts
4. Inspection and Sorting of all Parts
5. Reconditioning of Parts and/or
Replenishment by new Parts
6 P d t R bl
7
Final Testing
6. Product Reassembly
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Table of Contents
Introduction
TrendTowardsMechatronics andElectronics
CANReman ResearchProject
Example:ElectroHydraulicPowerSteering(EHPS)
Conclusion
Chair Manufacturing
and Remanufacturing
Technology
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CAN-Reman Research Project
Testing and Diagnosis Technologies Development
for Car Mechatronic and Electronic Remanufacturing
Project consortium
Project aims
Understanding the functionality of data
communication in vehicles (CAN Bus).
Operation and testing of mechatronic and electronic Operation and testing of mechatronic and electronic
systems independent from the car (simulation of the
vehicle by appropriate software).
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Development of a test bench for electronic and
mechatronic systems for remanufacturers.
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Partners CAN-Reman
Picture: Kick-Off-Meeting: 31th March 2009
10
Picture: WorkshopHands-on: 5th October 2009 Picture: Workshop Theory: 5th October 2009
Chair Manufacturing
and Remanufacturing
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Table of Contents
Introduction
TrendTowardsMechatronics andElectronics
CANReman ResearchProject
Example:ElectroHydraulicPowerSteering(EHPS)
Conclusion
Chair Manufacturing
and Remanufacturing
Technology
UP
CAN Reman Project Structure
Acquisition of
Reference Systems
(TRW EHPS,
test vehicle) test vehicle)
Analysis of the
Reference Systems
Input (parameters)
Output (parameters)
Development of a
test bench
Analysis of pump
car interaction
Isolation of the pump
from the vehicle
Wiring
Involved controllers
CAN Bus simulation
Restbus simulation
Analysis of Sensors
PWM Signal
Simulation e.g. using
a signal generator
CAN Bus Analysis
Failure Memory
Analysis (CAN)
Possible failures
Erasing the memory
12
a signal generator
CAN Bus Analysis
Relevant IDs
CAN messages
Reduction of data
g y
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CAN Reman Project Structure
Acquisition of
Reference Systems
(TRW EHPS,
test vehicle) test vehicle)
13
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CAN Reman Test Vehicle (Polo 9N1)
VW Polo, 9N1
Model Year 2002
E i 1 2 Lit 47kW E i C d AZQ Engine: 1.2 Liter, 47kW, Engine Code AZQ
Only CAN powertrain and diagnostics interface
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Interaction of the CAN controllers in VWs Polo,
model year 2002
Source: Volkswagen AG (2001) SSP 263 Der Polo Modelljahr 2002, p.40,
Wolfsburg
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CAN Reman Project Structure
Acquisition of
Reference Systems
(TRW EHPS,
test vehicle) test vehicle)
Analysis of the
Reference Systems
Input (parameters)
Output (parameters)
15
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Analysis of the Electro-Hydraulic Power Steering (EHPS) Pump
1 1x Elec tronic housing 110x101x147 Alum inium
2 1x Rotor 95x117 Steel
3 1x Metall Ring ca. 40x30x5 Steel
4 1x Sealing gask et 14x8x1 Steel
5 1x Coil with electronic circuit 115x128x97 n.a.
6 4x T orx screws M3x12 Steel
7 2x Brack ets ca 30x15 Steel
Power Consumption: 2-3A
(idle) up to 100A (load case)
Revolution speed: 1100 rpm
7 2x Brack ets ca. 30x15 Steel
8 1x Pum p bas is 130x192x133 Alum inium
9 1x Ring 14x8x1 Steel
10 1x Circlip 8x10 Steel
11 1x Coupling 11x14 Steel
12 1x Pum p cab (below) with sealing gas k et 73x91x19 Alum inium
13 1x Pum p device (with???? 17x32x58 Steel/ Alum inium
(idle), 3400-4000rpm (load
case)
CAN IDs: 3D0 (status), 5DE
(
14 1x Pum p body 68x91x46 Alum inium
15 4x Allen screw M8x68 Steel
16 1x
Pum p cab (above) with sealing gask et+
pressure c ontrol valve 2x91x68 Alum inium
17 1x Sealing gask et 110 Alum inium
18 1x Clam p 110 Alum inium
19 1 Oil t k 128 110 PA66
(failure memory)
Diagnostics: Transport
protocol TP1.6 and KW1281
19 1x Oil tank 128x110 PA66
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1
8
1
8
5
1
7
1
5
1
6
2
7
1
0
1
2
1
3
9 6
1
4
1
9
3 4
1
1
Chair Manufacturing
and Remanufacturing
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CAN Reman Project Structure
Acquisition of
Reference Systems
(TRW EHPS,
test vehicle) test vehicle)
Analysis of the
Reference Systems
Input (parameters)
Output (parameters)
Analysis of pump
car interaction
Wiring
Involved controllers
17
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Linkage between Pump and Vehicle
Electrical connectors
Power feed (K30) Power feed (K30)
Plus terminal of ignition circuit
(K15) (K15)
Ground
CAN high (CAN-H)
CAN low (CAN-L)
Steering angle velocity sensor
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Source: Volkswagen AG (2001)
SSP 259 Die Elektro-Hydraulische
Servolenkung, p.8, Wolfsburg
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and Remanufacturing
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CAN Reman Project Structure
Acquisition of
Reference Systems
(TRW EHPS,
test vehicle) test vehicle)
Analysis of the
Reference Systems
Input (parameters)
Output (parameters)
Analysis of pump
car interaction
Wiring
Involved controllers
Analysis of Sensors
PWM Signal
Simulation e.g. using
a signal generator
19
a signal generator
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TRW Steering Angle Sensor (SAS)
Determines the steering velocity / steering input
Capacitive sensor
Rotation of the rotor results in a change of capacity
Output of steering angle velocity as Pulse Width Modulated
Source: Prof Brasseur G. (2008) Forschung an der
Fakultt fr Elektrotechnik und Informatik, in
h j l d G 0 G
(PWM) signal
Sensor is replaced by a generator with PWM (1kHz, width
10%-70%)
Forschungsjournal der TU Graz, p.10, Graz.
10%-70%)
20
Source: Volkswagen AG (2001)
SSP 259 Die Elektro-Hydraulische
Servolenkung, p.8, Wolfsburg
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and Remanufacturing
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CAN Reman Project Structure
Acquisition of
Reference Systems
(TRW EHPS,
test vehicle) test vehicle)
Analysis of the
Reference Systems
Input (parameters)
Output (parameters)
Analysis of pump
car interaction
Wiring
Involved controllers
Analysis of Sensors
PWM Signal
Simulation e.g. using
a signal generator
CAN Bus Analysis
21
a signal generator
CAN Bus Analysis
Relevant IDs
CAN messages
Reduction of data
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CAN Bus Analysis - CANoe
Determination and assignment of the IDs
to the different controllers (e.g. ABS,
airbag engine instrument panel) airbag, engine, instrument panel)
Analysis of the bus timing
Analysis and interpretation of the message Analysis and interpretation of the message
body
Investigation of the different signals that
are incorporated in a message
Emulation of the messages
Development of a vehicle CAN database
Setup of a communication matrix
22
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and Remanufacturing
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CAN Reman Project Structure
Acquisition of
Reference Systems
(TRW EHPS,
test vehicle) test vehicle)
Analysis of the
Reference Systems
Input (parameters)
Output (parameters)
Analysis of pump
car interaction
Wiring
Involved controllers
Analysis of Sensors
PWM Signal
Simulation e.g. using
a signal generator
CAN Bus Analysis
Failure Memory
Analysis (CAN)
Possible failures
Erasing the memory
23
a signal generator
CAN Bus Analysis
Relevant IDs
CAN messages
Reduction of data
g y
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Vehicle Diagnostics via CAN
Investigation of the diagnostics via CANoe
Analysis and emulation of the transport protocol TP1.6
Analysis and emulation of the diagnostics protocol
KW1281
Determination of conversion formulas for physical
measurements
Implementation of user interfaces (panels) Implementation of user interfaces (panels)
24
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CAN Reman Project Structure
Acquisition of
Reference Systems
(TRW EHPS,
test vehicle) test vehicle)
Analysis of the
Reference Systems
Input (parameters)
Output (parameters)
Analysis of pump
car interaction
Isolation of the pump
from the vehicle
Wiring
Involved controllers
CAN Bus simulation
Restbus simulation
Analysis of Sensors
PWM Signal
Simulation e.g. using
a signal generator
CAN Bus Analysis
Failure Memory
Analysis (CAN)
Possible failures
Erasing the memory
25
a signal generator
CAN Bus Analysis
Relevant IDs
CAN messages
Reduction of data
g y
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Isolation of the Pump and Restbus Simulation
Setup of a restbus simulation in CANoe
Simulation of all controller IDs and of the relevant signals
Simulation of the presence of all CAN bus devices
Transfer of the restbus simulation to a microcontroller
Result: Isolation of the pump from the vehicle
26
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and Remanufacturing
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CAN Reman Project Structure
Acquisition of
Reference Systems
(TRW EHPS,
test vehicle) test vehicle)
Analysis of the
Reference Systems
Input (parameters)
Output (parameters)
Development of a
test bench
Analysis of pump
car interaction
Isolation of the pump
from the vehicle
Wiring
Involved controllers
CAN Bus simulation
Restbus simulation
Analysis of Sensors
PWM Signal
Simulation e.g. using
a signal generator
CAN Bus Analysis
Failure Memory
Analysis (CAN)
Possible failures
Erasing the memory
27
a signal generator
CAN Bus Analysis
Relevant IDs
CAN messages
Reduction of data
g y
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and Remanufacturing
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Test Cycles
1. Electrical inspection of the pump using our CAN controller
Reading and erasing the failure memory
Coding of the pump for a defined operation mode
Restbus simulation of all participating CAN controllers
Simulation of steering input by variation of the PWM signal
2. Inspection of the pump performance (flow rate and pressure)
Fully automated setup of the measurements
Fully automated recording of the measurements
28
Permanent monitoring of the operating condition
Fully automated evaluation of the measurements
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The Technological Change in our Test Benches
Test Bench for Electro-hydraulic Power Steering Pumps
Generation I Generation II + III
Dimensions (L x W x H): 1200 mm x 800 mm x 970 mm
Automotive specific values: voltage, current (100A), oil flow rate (16 l/min) and oil pressure (120 bar)
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Automotive specific values: voltage, current (100A), oil flow rate (16 l/min) and oil pressure (120 bar)
CAN controller: AT90CAN128 (one CAN channel)
Updates for future pump models will be available on demand
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Table of Contents
Introduction
TrendTowardsMechatronics andElectronics
CANReman ResearchProject
Example:ElectroHydraulicPowerSteering(EHPS)
Conclusion
Chair Manufacturing
and Remanufacturing
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Remanufacturing of Automotive Mechatronics
Remanu-
CAN Bus
Know-how
Remanu-
facturing
Technolo-
gies
Diagnostics
g
31
Tools for Remanufacturing of Automotive
Mechatronic and Electronic Parts
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TTHANK HANK YYOU OU
foryourattention!
MatthiasAlbrecht Dr.StefanFreiberger
32
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