Difficulties in Aftermarket Data Release

OEM and Aftermarket ConcernsScott Bolt – Chief Engineer MAHLE Test Systems

19 April 2012

2

MAHLE Overview

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Worldwide Locations

USA Ann Arbor (MI) Atlantic (IA)

Farmington Hills (MI)

Franklin (KY) McConnelsville

(OH) Morristown (TN)

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Olive Branch (MS) Russellville (AR) St. Johns (MI) Trumbull (CT) Winterset (IA)

Canada Niagara-on-the-

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Mexico Aguascalientes

Lerma Naucalpan

Ramos Arizpe Santa Catarina

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Aires Rafaela

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Itajubá Jundiai Limeira

Mogi Guaçu Queimados

São Bernardo do Campo

Great Britain Bathgate

Kilmarnock Northampton

Rugby Stoke-on-Trent

Telford Wellingboroug

h Worcester

France Chavanod Dardilly Décines Ingershei

m Orange Poissy Rungis

SeboncourtSpain

Alcalá de Henares/Madrid

Vilanova I la Geltrú

Portugal Murtede

Switzerland Grenche

n

Italy Bomasco LaLoggia Saluzzo Trento

Germany Albershausen

Alzenau Barsinghausen

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Schorndorf Stuttgart

Wölfersheim Wustermark

Zell im Wiesental

Poland Krotoszy

nAustria

Mattighofen Rankweil

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Slovakia Dolný Kubí

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Turkey Gebze Izmir Konya

India Gurgaon

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Parwanoo Pithampur

Pune

China Changchu

n Chongqing Guangzho

u Macheng Nanjing

Shanghai Tianjin Yingkou

Thailand Bangkok

Samutprakarn

Philippines

Cavite

Korea Hwasun

g Ulsan

Japan Fukushim

a Ibaraki

Kawagoe Okegawa Tochigi Tokyo

Tsuruoka Yamagata

Australia Laverton

North/Melbourne

Production locations R&D centers

April 2008

Netherlands Alkmaar Lochem

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Worldwide Research - Development - Testing

StuttgartDetroit (Farmington Hills)

Detroit (Novi)

São Paulo

Tokyo (Okegawa)

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Shanghai

Northampton

1998

2004

1997

2004

2006

2002

2001

Around the world, approximately 3,000 development engineers and technicians are working on future concepts, products and systems for ongoing development of vehicular innovation.

Jundiaí

2008

MAHLE Test Systems

Over 9000 Dealership Locations

46 Vehicle Manufacturing Plants

5 Continents

32 Languages

65 Vehicle Lines

>8 Million Vehicles Tested/Year

History

ECMAftermarket Tool

ManufacturersOEMTool

Engineering

ETI

• Clear Codes, Read Codes, Read Data

• Communication Setup

You must supplythem the “data”

History

ECMAftermarket Tool

ManufacturersOEMTool

Engineering

ETI

• Code List• Data Stream• Communications Info

Information Needed By Tech No Problem!

History

GatewayAftermarket Tool

ManufacturersOEMTool

Engineering

ETI

• Code List• Data Stream• Communications Info• Buss ECU’s are on• Special procedures• Reprogramming• Learn and Setup

procedures• Service Information Data

Information Needed By Tech

You must supplythem the “all the data”

• VIN• Diagrams• Lots of “questions” about vehicle (ie

Heated Seats? Dinglehopper position?)

• Output Control Data• Data Sharing Information• ECU selection• Special security interfaces• Cross-ECU testing

ECM

BCM

???

?

History

• The number of ECU’s has risen greatly (from 1 to over 100)• The electrical architecture has become very complex (from a single line to

many lines on many gateways to many ECUs).• The amount of data each ECU can access is much greater (from 10 to over

1000)• The number of functions that must be performed to diagnose a vehicle has

greatly increased (from 3-5 to hundreds)

Diagnostic Data

Simple data was stored in a simple format

YearMakeModel

ECU Data Stream

DTCs

Comm Info

All information needed to identify the correct set of information for a vehicle could be derived from the VIN or from asking the repairman

Diagnostic Data

The huge increase in complexity of the vehicle caused the OEMs to store their information in ever more complex ways in order to retain the ability to handle such large volumes of complex information

• ECU information is stored in a “virtual” ECU shared by many vehicles with only some differences

• Vehicle information is stored in a “virtual” vehicle shared by many physical vehicles with only some differences

• These differences are controlled by rules.

Diagnostic Data

YearMakeModel

PCM1 Data Stream

DTCs

Comm Info

PCMEngine Size

Engine FamilyPart Number

PCM2 Data Stream

DTCs

Comm Info

PCM ‘N’

Data Stream

DTCs

Comm Info

Data Stream Rules

DTC Rules

Comm Info Rules

Data Stream Rules

DTC Rules

Comm Info Rules

Data Stream Rules

DTC Rules

Comm Info Rules

• Rule based data relationships are complex

• Information needed to resolve the rules is difficult or impossible for a repairman to answer

• OEM tool strategies used to resolve the rules are not always documented

• In addition to the diagram, several other items can be rule controlled

• Output controls, their pre-conditions, run conditions, and final reset functions

• Test menu and sub menus• Configuration/Setup data

Diagnostic Data

There are other systems that must also be used which have a host of input variables required in order to accurately resolve their rules:

• Security Systems• As Built/As Configured systems• ECU Reprogramming Systems• Information Systems

Possible Solutions

EC

U D

ata

Standardized Ruie Input

Shop Tool

Veh

icle Bu

ild S

ystem

As Built/As ConfiguredSecurity SystemsECU Programming

Stan

dard

ized B

uild

In

terface

Information System

Stan

dard

ized D

ata In

terface

Standardized VCI Interface (J2534/J22900)

VCI Device

Challenges

• Different OEM’s store their information in different tool architectures• Putting the data into a standard flexible enough to hold any kind of OEM data

for any kind of ECU is very challenging (and expensive)• This data format is not useful to the OEM (beyond their current formats) so the

charge would likely be passed through to the aftermarket

OEM Scan Tool Data

OEM Build Interface

• Different OEM’s store their information in different formats

OEM Rule Interface

• Aligning all systems with the exact same input (ie “Year” is different than “MY”)

Thank You!