support of electric/electronic diagnosis in production for passenger car project in china vilmos...

Support of Electric/Electronic Diagnosis in Production for

Passenger Car Project in China

Vilmos Zsombori

21.01.2005, Shanghai

Support for Diagnosis in Production

Automotive ELECTRONICS

1 Overview

3 Possible Tasks for Us

2 ECU Diagnosis in Production

4 Work Phases

5 What We Need



Overview

Mercedes-Benz C-Class and E-Class passenger cars will be produced in China beginning from the year of 2005

The following key issues occur for the production line set-up in China regarding the diagnosis system: To build up the know-how Configure and deploy the environment Adapt and test the applications

Stable, robust routine operation, and immediate technical service should be strictly guaranteed

DaimlerChrysler SIM Tech. should be closely involved in these tasks

1 Overview 2 3 4 5



1 Overview



4 Work Phases

5 What We Need



The IS Tester

In passenger car production, the IS tester diagnostic system is used There are four key tasks for testing operations using the IS tester:

Test whether the ECU is functional (self-diagnosis) Test whether all of the sensors and final control elements are functional and the

wiring has been done properly (functional test) Test whether the correct ECU has been installed in the vehicle Load coding data to customize the ECU to the vehicle

The diagnosis system: Hardware

industrial PC connected to the diagnostic jack communication hardware device (coupling card), printer

Software NISP (New IS Tester Program)

2 ECU diagnosis1 543



Where Testing is Done

Trim Line (Assembly) The station where the ECUs are typically coded; partial testing

Chassis (Assembly) Sensors and final control elements are tested

Finishing (Assembly) Extras (e.g. anti-theft protection system) are tested

Roller Tester The vehicle needs to be driven (dynamic tests)

Engine Check Rework Special Tests




Testing Operations

Adaptation The vehicle needs to be unambiguously identified for the testing system. The production number is transferred to the testing system over a

PC-SPC coupling

ECU Test All the ECUs are put into diagnostic mode Based on the vehicle data set, the system checks whether the right ECUs

have been installed in the correct places.

Functional Test Made up of all the steps where communication with the ECU in diagnostic

mode is effected in order to check that it is operating trouble-free In some cases, test personnel are required to perform actions that should

be detected by the ECU.2 ECU diagnosis1 543



Testing Operations (ctd.)

Coding Many ECUs are codable, i.e. the vehicle is adapted to the ECU. The coding information is either read out of the ECU-specific coding files

or gathered during the testing operations on the basis of the vehicle data record.

Documentation A test label is output for documentation of the testing operations. The label lists all the ECUs tested, together with the part IDs, software

releases, and errors returned. The label is stuck onto the assembly documents, which are archived. At the same time, the label data and other result data are transferred to a

central archive for statistical evaluation of the tests performed.




NISP – Components Making up the Application





Core system, test program, compiler and interpreter The NISP core system (PAH) executes the test program, and it is

controlled by the control table. The control table contains a number of basic functions (handler functions)

and control constructs (loops, assignments, conditional branches). The test program is created in a general language PAS (test application

language) and then converted into the binary format needed by the test program compiler (PAC).

Communications processors are required for the communication with the ECUs. The devices used are the CAESAR communications modules.





Test application generator A graphical tool – the test application generator PAG – is also provided It allows graphical objects to be combined to create a test program. This

approach is quick and easy and does not necessitate expertise in the programming language.

The tool is facilitating a clear overview of the overall scope of operations and aims preventing syntactic programming errors, allowing testing personnel with no programming know-how to create a test program.

It does not provide assistance in placing the individual testing sequences in the correct logical order.

Therefore, a great deal of experience is the key factor in designing a good test program, either by using the graphical tool, either creating by hand.





Vehicle and ECU description data The ECU description data – DIOGENES data (or SET files) – sets out the

byte strings necessary for access to the related ECU information and how the responses are to be interpreted.

The vehicle data is used to detect the vehicle-specific parts to be tested and for generation of the vehicle-dependent coding information necessary for most of the ECUs.

IS Tester Server UNIX system supported by a database; gathers all the result data and

interprets it. The primary source of vehicle data for the test system.




The NISP Environment




NISP – Overview of Technical Features

Graphical creation tool and problem-oriented standard language for testing operations. Enables parallel communication with several ECUs. Multiplatform support for the intermediate code (DOS, Windows, UNIX). Combination of ECU testing (serial) with testing of the electrical system (consumer test, ECOS). Several testing operations can be run separately with manual or automatic selection. Multilanguage capability through deployment of text files for output texts with referencing done by

assigning numbers. GUI with specific add-ons (operation via remote control). Network integration; remote maintenance. Generation of quality and/or statistical data. Configurable printer functions (label printout). Auto-recognition of ECU variants. Rework functions (dynamic menus as per the relevant error state). Emission-related test jobs required for issuance of official certificates may be recorded if desired. 32-bit DOS application in protected mode; cooperative multitasking (RT Kernel)




NISP – Overview of Technical Features

Diagnostic protocols: Kühner (MB-Iso) Keyword FB Keyword 2000 (passenger cars and trucks) RTMD+ Free-Running

Communication hardware: CAESAR module(s) Parts A, B, C (recommended) CAESAR Part C/IR infra-red interface BaRa 4x coupling cards (Coupling cards via V24)

System requirements (for NISP 5.0 and later): Minimum requirements Pentium 133 (recommended: 300 MHz or faster), 64 MB RAM, 100 MB hard disk ISA port for CAESAR Part C




1 Overview



4 Work Plan

5 What We Need



Possible Tasks for Us

Multilanguage support

Although multi-language capability is offered by NISP through the deployment of text files for output texts with referencing, there is no Chinese version available up till now. The development of Chinese add-ons (output texts, specific graphical user interface, technical documentation) is necessary for the local production both for the line diagnoses and the repair services in the workshop.

3 Possible Tasks for Us 5421

DaimlerChrysler SIM Technology Co. Ltd. should be closely involved in the following tasks and services for reasons of localization and in-house knowledge to bridge the possible problems that may be encountered:





Setup, modification and adaptation

There are some possible modification expected due to the plant relocation (to be found out during the road test). These modifications will affect the diagnosis system as well, so, the task of adaptation and configuration of hardware/software will have to be handled.

Training

Even though the sequence of operations is predefined, line staff is responsible for supervising testing. And, in some cases, testing is interactive: the test program requests testing personnel to perform specific action. Therefore testing personnel have to undergo a thorough training to be able to perform:

routine operations using the IS Tester, documentation, adaptation or alteration of test sequences.





Maintenance and technical services

Engineers from DaimlerChrysler SIM Tech. could provide after-setup technical services and monitoring to guarantee a continuous availability of the overall diagnosis system. Tasks include:

adaptation or redefinition of test sequences on necessity, monitoring and supervising the diagnosis, maintaining and supervising the IS Tester server, reporting and communicating with DaimlerChrysler engineers for trouble-

shooting.



1 Overview



4 Work Plan

5 What We Need



Work Plan

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1 Overview



4 Work Plan

5 What We Need



What We Need for Preparation

Guidelines Documentation:

A thorough description of the following protocols: MB-Iso, Keyword FB, Keyword 2000, RMTD+, CAN protocol communication protocol between the testing stations and the server

Technical documentation of the latest NISP system (PAH, PAG, PAS, Test Server) Vehicle and ECU description data structures

Hardware: CAESAR module(s), Coupling cards Sample ECU

5 What We Need4321

In order to prepare for a possible start, we would need the followings:



What We Need for Preparation

Software: The NISP Test program setup system (PAG + PAC) The NISP Runtime system (complete core – including the RT kernel) The ECOS Setup system + ECOS Test step editor + ECOS Runtime system IS Tester Server software, the administration tool and the analysis/statistics and

visualization tool

Data: Sample test programs in text format (PAS), as well as created by the graphical tool

(PAG) Sample vehicle and ECU data (CAESAR/DIOGENES) Sample queries (IS Tester Server)

5 What We Need4321

In order to prepare for a possible start, we would need the followings:

support of electric/electronic diagnosis in production for passenger car project in china vilmos...

Documents

ecu diagnosis

ecu test

diagnosis system

functional test test

test label

production number

testing system

test personnel