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Product Training Airbag Volkswagen Group

Airbag System /
Airbag Control Units
+ Satellites
Product Training Airbag VW

Page 1

SV C RS Q1 - M. Brger 07/04

Product Training Airbag Volkswagen Group

What means Safety Electronics?

Airbag control units decide in case of a crash event,


whether the belt pretensioner and airbag moduls will be fired or not.
Airbag control units check steadily the whole airbag system in a car.

Airbags should save life, not injure life!


Complete protection by front, side, head airbags and belt pretensioner.
Product Training Airbag VW

Page 2

SV C RS Q1 - M. Brger 07/04

Product Training Airbag Volkswagen Group

Front airbag deployment (pictures from high speed camera!)

10 ms after deployment

15 ms

30 ms

1 ms = 1 milli second!

Product Training Airbag VW

Page 3

SV C RS Q1 - M. Brger 07/04

Product Training Airbag Volkswagen Group

Safety systems have active and passive components

Active: Airbag system,


ABS, ESP ...
Passive: Constructive protection of the
car body and a secure passenger cell
Product Training Airbag VW

Page 4

SV C RS Q1 - M. Brger 07/04

Product Training Airbag Volkswagen Group

Airbag systems contain electronic control units,


satellites, airbag moduls and belt pretensioner

Driver module in the steering wheel, passenger module in the dash board

Product Training Airbag VW

Page 5

SV C RS Q1 - M. Brger 07/04

Product Training Airbag Volkswagen Group


Cross section from a
complete driver airbag
module with a folded
airbag

Cross section from a


airbag module with
firing squip and gas
inflator

collector ring

Product Training Airbag VW

Page 6

SV C RS Q1 - M. Brger 07/04

Product Training Airbag Volkswagen Group


Driver front airbag
inflators

several squips

Passenger front airbag


inflators
Product Training Airbag VW

Page 7

SV C RS Q1 - M. Brger 07/04

Product Training Airbag Volkswagen Group


Data transfer by
CAN network

end of line
programming

AWL

crash output
HW-control

engine
management

diagnosis
interface

combiinstrument

CAN signal high, low


ESP

airbag control unit VW61


(VW8R)

comfort
control unit

telematic
(navigation)

Product Training Airbag VW

Page 8

Check of periphery by
"Stellgliedtest" with
VAG/VHS-Tester possibl

SV C RS Q1 - M. Brger 07/04

Product Training Airbag Volkswagen Group


external sensors

central control unit

parameter setting

hardware
power supply, firing circuits

controller

front, side satellites


passenger detection

airbag control unit with


SRE, SFA algorithm

crash
parameter,
car
application,
configuration
stored in
EEPROM
MFT end of line file out of
Freigabetabelle

Airbag System supplied by Siemens VDO


Product Training Airbag VW

Page 9

SV C RS Q1 - M. Brger 07/04

Product Training Airbag Volkswagen Group


Acceleration side satellitesg-Sat3 front

Airbag control unit VW61 (central unit)


for side and head airbags
Acceleration side satellitesg-Sat3 rear

Airbag System supplied by Siemens VDO


Product Training Airbag VW

Page 11

SV C RS Q1 - M. Brger 07/04

Product Training Airbag Volkswagen Group


Acceleration satellitesg-Sat4
Front satellites
ECS4

Airbag control unit VW8R (central unit)


for side and head airbags
Front crash sensors = early
crash only for NAR market
Pressure satellites p -Sat4

Airbag System supplied by Siemens VDO


Product Training Airbag VW

Page 12

SV C RS Q1 - M. Brger 07/04

Assembly of the airbag control units and satellites in the vehic le, example VW Golf

g-satellite
g-satellite
Control unit

Screwed on the middle tunnel

control unit
Product Training Airbag VW

Page 13

SV C RS Q1 - M. Brger 07/04

Assembly of the airbag control units and satellites in the vehic le, example VW Passat
Belt pretensioner
Satellites

Steering wheel with


front airbag module

Collector ring
Side/ Headairbags
front and rear

Control unit

Side/ Headairbags
Passenger airbag mod

Satellites
Belt pretensioner

Product Training Airbag VW

Page 14

SV C RS Q1 - M. Brger 07/04

Product Training Airbag Volkswagen Group

Airbag control unit VW61 (central unit)

Acceleration satellitesg-Sat3 front

Airbag mod
Acceleration satellitesg-Sat3 rear

Belt pretension

Diagnosis interface

Airbag System
Product Training Airbag VW

Buckle switches

CAN-bus
Key switch
Warning lamps
Battery deployment unit
Crash output
Wiring harness + connections
Collector ring
Page 15

SV C RS Q1 - M. Brger 07/04

Product Training Airbag Volkswagen Group


Functions of an Electronic control unit (ECU) VW3, VW51/52, VW61/62
- Crash identification
- Identification in x- (front) and y - (side) direction with integrated xy-g-sensor
- Micro mechanic capacitive g-sensor (differential moveable capacitor)
- Additional side crash identification with external side satellites (g -satellites)
- Crash memory
- Mechanical saving switch
- External and internal failure detection of the complete airbag system
- EEPROM fault memory
- Diagnosis function / communication via CAN-Bus or K-Line
- End of line programming function (vehicle specific crash parameters)
Product Training Airbag VW

Page 19

SV C RS Q1 - M. Brger 07/04

Product Training Airbag Volkswagen Group


Crash Sensing in control units and satellites:
Micromechanical acceleration sensing
SMD Component
1.3
Micron
Gap

2 Microns
Thick

Siignal
gna
l

Product Training Airbag VW

Page 25

SV C RS Q1 - M. Brger 07/04

Product Training Airbag Volkswagen Group


leadframe
gel
coverage

Micromechanical
acceleration sensing
with Motorola SX 3209
for VW3, VW51, 61, 62

g-cell for
acceleration
sensing

g-cell with silicon gel


coverage + amplifier asic
on not separated metal
leadframe
Nominal output voltage: 2,5V
Spec. limit in ECU: 2,1 - 2,9V
Product Training Airbag VW

Page 26

Filter/amplifier asic
creates the
electrical output
signal
SV C RS Q1 - M. Brger 07/04

Product Training Airbag Volkswagen Group


Micromechanical
acceleration sensing
with AnalogDevices
ADXL78/278 for VW8,
81, 8R, AUDI8R

g-cell with 2 moveable


structures
(differential capacitor)

Single-Chip incl.
g-cell + asic

Product Training Airbag VW

Page 27

SV C RS Q1 - M. Brger 07/04

Product Training Airbag Volkswagen Group


differential
capacitor
moveable mass

Speed change
= exterme
braking, crash
= negative
acceleration

Movement of the
sensing element
due to inertia
(moveable mass)
= moveable
electrical
capacitor

Change of capacity
at capacitor causes
a change of the
voltage ouput at the
capacitor
= change of the
electrical signal

Change of signal at
asic input causes an
a change of the
amplified signal
output
= information
for the controller

Note: Everyone can experience this inertia effect in the car while br aking, the human
body and other things are following the direction of the front movement => the body
will be moved forward => the differential moveable capacitor will do the same!
Product Training Airbag VW

Page 28

SV C RS Q1 - M. Brger 07/04

Airbag control units VW61/62, electrical main components / funct ions


front
airbag
driver

front
airbag
pass.

side
airbag
driver
front

side
airbag
driver
rear

side
airbag
pass.
front

side
airbag head
pass. airbag
driver
rear

head
airbag
passenger

4-Loop SPI ASIC


2-LAooSpIC

Ubatt
Combined ASIC V1 - 3

GND
K-line

belt pretensioner
driver front

safing sensor

AWL
invers

X-Sensor

pass.- deact WL
front /side
airbag

Microcontroller
MC68HC912D60(A)

4-Loop
SPI
ASIC

belt buckle
switch driver
belt buckle
switch pass.

Interface

pass. deact. switch


front / side airbag

Product Training Airbag VW

CAN- Bus

Interface

crashoutput

Interface

side
satellite
front
right

Interface

side
satellite
front
left
Page 29

Interface

Interface

side
side
satellite satellite
rear
rear left
right

belt pretensioner
passenger front
belt pretensioner
driver rear *)
belt pretensioner
passenger rear *)

*) for version with


12 firing loops,
actually not in
use @ VW
SV C RS Q1 - M. Brger 07/04

Airbag control units VW61/62, electrical main components / funct ions


Controller

Satellite
Interfaces

Energy reserve,
capacitors
xy Acceleration sensor

Mechanical
Firing asics

Satellite signals
Product Training Airbag VW

safing sensor

Firing voltages
Page 30

SV C RS Q1 - M. Brger 07/04

Airbag control units VW61/62, electrical main components / funct ions


Firing asics (Infineon V1-3, 4Loop, 2Loop)
-> integrated firing circuits with separate high and low side switches, voltage supplies

Controller (Motorola HC12)


-> contains control unit program, crash algorithm, EEPROM failure memory

Satellite interface asic (Temic U6268B)


-> transforms current signal from satellites into a voltage signal for controller input

Safing sensor (Hamlin 041)


-> mechanical reed switch -> contacts will close in case of crash situation for front airbags

Acceleration sensor (Motorola SX 3209)


-> transforms mechanical movement (negative acceleration) into in electrical signal

Electrolytic capacitors
-> contain firing energy, voltage supply in case of interruption of battery connections
Product Training Airbag VW

Page 31

SV C RS Q1 - M. Brger 07/04

Assembled panel VW61

Example
5Wk 43131
1C0 909 605 F
10 Firing Loops =
2 Front airbags
4 Side airbags
2 Head airbags
2 Belt pretensioner

Product Training Airbag VW

Page 32

SV C RS Q1 - M. Brger 07/04

Assembled panel VW51

Example
5Wk 43122
1C0 909 605 A
6 Firing Loops =
2 Front airbags
2 Side airbags
2 Belt pretensioner

Product Training Airbag VW

Page 33

SV C RS Q1 - M. Brger 07/04

gSat3 side satellites for sensing of the y-direction in vehicles

Side satellites are detecting the side accelerations of a vehicle; in every vehicle with
side application are in minimum 2 satellites installed; the satellites have an own
internal crash algorithm, which creates an own firing decision. This firing signal will be
transmitted to the control unit and be checked/compared with the result of the crash
algorithm of the control unit. The unit will decide about the firing of the airbag moduls.
Product Training Airbag VW

Page 35

SV C RS Q1 - M. Brger 07/04

gSat3 side satellites for sensing of the y-direction in vehicles


6Q0 909 606

satellite pre
assembled

gSat3 front
Assembly
direction 90 to
driving direction
1C0 909 606
gSat3 rear

satellite
molded

Assembly
direction in
driving direction

Product Training Airbag VW

Page 36

SV C RS Q1 - M. Brger 07/04

gSat3 side satellites for sensing of the y-direction in vehicles


gSat3 layout assembly, components

Acceleration sensor,
Analog Devices

mechanical coding
resonator

voltage regulator

sensing
direction

Controller
PCB: front
Product Training Airbag VW

rear
Page 37

SV C RS Q1 - M. Brger 07/04

gSat4, ECS4 layout assembly, components


poly-urethane
potting

PCB
Sumitomo
connector
press-fit pins

marking molded into housing:


bushings for
M6
screw
Product Training Airbag VW

VW-Logo, VW part number,


measurement direction arrow,
Siemens MLFB number,
PBT GF30, Siemens VDO

Page 38

SV C RS Q1 - M. Brger 07/04

gSat4, ECS4, sensor functionality


existing g-cell (x,z)

input
acceleration

g-cell
g-cell

data
data
conditioning
and
state machine

ATIC56

memory

auxiliary circuits
(power supply,
clock generator)

interface

ATIC56
raw data
to the ECU

ATIC55

Product Training Airbag VW

new ASIC
Page 39

existing package
SV C RS Q1 - M. Brger 07/04

pSat4, pressure sensor, layout assembly, components


Pressure based Side Impact Satellite

poly-urethane
potting

SIS (p)

General Characteristics
unique electronic serial number
water protection class
supply voltage (max. rating)

IP53
- 16...20 V

supply voltage (op. range)


supply current
signal current

6...12 V
5...8 mA
25...38 mA

PCB

Sensing Characteristics
temperature range
ambient pressure range
measurement range
dynamic range

molded TPE
sealing rings

-40+85C
600 to 1300 mbar
-24 to +107 mbar/bar
0.3...360 Hz

self test: comparison of two independent pressure cells on chip


Time to fire of pressure based in comparison to acceleration bas

ed sensing

Crash Signal
Car to Car 30km/h
(JAP/AUS/EURO NCAP)

80
60
40

gSAT pSAT

press -fit pins

SSiigg
nnaall

Pressure
Acceleration

20

silicone seal
for pressure sensor

0
20
40
0 2
- 26
60

10 12 14 16 18 20 22 24
t

Fire Pressure

28
Time in ms

Fire Acceleration

Sumitomo
connector

Product Training Airbag VW

Page 40

SV C RS Q1 - M. Brger 07/04

Airbag control unit VW8/81, function flow during front crash


Driver
Airbag module

Crash
t=0s

125 mm ~ 50ms

t = 50 ms
30 ms

Airbag
Airbag control unit

Capacitor/Energy Reserve

firing
squip

Gas
generator

T8xx

Safing Transistors
ASIC with high/low side switch
High side sw

xy -/ - x
g- sensors

V200
Controller

Connector
Product Training Airbag VW

V100

H300

low side sw
Page 44

SV C RS Q1 - M. Brger 07/04

Airbag control unit VW61/62, function flow during front crash


Driver
Airbag module

Crash
t=0s

125 mm ~ 50ms

t = 50 ms
30 ms

Airbag
Airbag control unit

Capacitor/Energy Reserve
Gas
firing
squip

H100

Hamlin
ASIC with high/low side switch

generator

High side sw

xy -g- Sensor

V200
Controller

Connector
Product Training Airbag VW

V100

H300

low side sw
Page 45

SV C RS Q1 - M. Brger 07/04

Airbag control unit VW61/62, function flow during front crash


Airbag control unit

Airbag

Capacitor/Energy Reserve

firing
squip

Gas
generator

H100

Hamlin
ASIC with high/low side switch
High side sw

xy -g- Sensor

V200
Controller

Connector

V100

H300

low side sw

1) Micromechanic g-sensor recognizes a crash signal (mechanical movement);


2) Controller checks the signal, takes the decision whether firing or not;
3) Mechanical safing sensor (reed switch) closes due to the acceleration;
4) Firing asic closes electronical high and low side switch by controller commando;
5) Current flow from capacitor over safing sensor and asic to firing squip to ground;
Product Training Airbag VW

Page 46

SV C RS Q1 - M. Brger 07/04

Airbag control unit VW61/62, function flow during side crash

Airbag control unit


Capacitor/Energy Reserve

firing
squip

ASIC with high/low side switch

Gas
generator

High side sw

xy -g- Sensor

V200
Controller

Connector

V100

low side sw
V600

Product Training Airbag VW

H300

V620

Satellite
interfaces

Page 47

SV C RS Q1 - M. Brger 07/04

Airbag control unit VW61/62, function flow during side crash


Airbag control unit

1) Satellite with micromechanic g-sensor recognizes a


crash signal (mechanical movement)
2) Satellite controller checks the signal, takes the decision

xy -gSensor

firing
squip
V100

whether firing or not

V200
Controller

H300

V600V620

3) Satellite sends a fire signal to the airbag control unit


4) Micromechanic y-g-sensor recognizes the same crash
signal (mechanical movement = acceleration)
5) Controller checks the signal, takes the decision whether firing or not;
6) Controller checks the satellite decision, if satellite and controller confirm the crash
7) Firing asic closes electronical high and low side switch by controller commando;
8) Current flow starts from capacitor over asic to firing squip to ground;
Product Training Airbag VW

Page 48

SV C RS Q1 - M. Brger 07/04

Airbag control unit VW61/62, how the electrical periphery in the car looks like?
Satellite
pass. rear

Side airbag
passenger rear

Side airbag
driver rear

Head airbag
passenger side
Satellite
pass. front

Head airbag
driver side
Satellite
driver rear

Belt pretensioner
passenger

Belt pretensioner
driver
Side airbag
driver front

Side airbag
passenger
front
Key switch for passenger
front airbag deactivation

Satellite
driver rear

Buckle Switch
passenger

Buckle Switch
driver

Front airbag
passenger
Passenger LED
CAN Bus
Warning lamp

Front airbag
driver

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