2008 testing automotive mechatronics
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PTM Electronics
Testing Mechatronics,
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Mechatronics (or Me c h a nical
an E ect r o n i c s Engineering sthe combination of mechanical
engineering, electronic
computer/control engineering.
Mechanical
Computer
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In terms of computing Typical Electronic Control Units
,now contains the roughequivalent of 50 to 100small laptop computers in
Antilock Brake Controls & Stability Control Systems
Air Bag Control Modules
Antenna Modules
,and these are linked toeach other by as many as10 computer networks.
Body Computer Modules
Driver Information Centers
A luxury sedan has between10 and 15 million lines ofembedded software codethe same amount required
Engine Control Modules
Head Up Displays
by a Boeing jet as recentlyas 1997.
HVAC Control Modules
Instrument Panel Clusters
Personal Occupant Detection Modules
Power Train Controllers
Power Controllers (Liftgates, Windows, Convertibles)
Radio and Navigation Units
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Mechanical Devices
, , For an ABS system solenoid activated valves, hydraulic pumps and lines, disks,
pads, mounting systems
Cases/Enclosures Mechanical assemblies levers, gears, shafts, springs, wheels Connectors
Electronics Printed Circuit Board Assemblies
Electronics (Resistors, Capacitors, Transistors, Diodes, Transformers, Integrated, ,
Connectors Power Supplies Lights/LEDs Photo Diodes
ompu ers Processors Memory Communications Devices
Sensors/Actuatorsempera ure, ressure, ra n,
Solenoids, Motors, Relays
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Three basic reasons for failure
Design Flaw (Mechanical, Electronic, Software) Environment
Vibration Temperature Shock Elements Dust, Water, Salt
Ph sical Electrical Abuse
Mechanical wear/stress Connector make/break Stress on PCBs Electrical Event
Shorts
Electrostatic Charge Polarity reversal Over voltage
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Re lace
New
OEM $$$$
Availability
After Market $$$
Repair
Remanufactured $$
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and consumers
Lowers replacement/repair cost
Keeps PCBs out of Land fills Allows OEMs to meet the 15 Year
availability self imposed guideline
But how does the remanufacturermeet the challenges
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Meetin Ex ectations:
At a Minimum the consumers Expectations
The OEM or Tier One specifications Isolating Faults and verifying the fault has been
repaired
different vehicles, model years, and designs
Finding Sufficient Supplies
Cores
ICs er ep acemen componen s
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1. Receive Cores or Defective Units
2 . So r t & Cl a s s i f y Go o d / B a d Un i t s
3 . D i a g n o s e Fa u l t s an epa r
4 . V e r i f y Go o d & R e p a i r e d U n i t s m e e t
em a n u a c u r e r s s a n a r s
5. Clean and refurbish physical components
6 . P r o g r am r em a n u f a c t u r ed u n i t s t o m a t ch cu s t om e r
o r d e r r e q u i r em e n t s
7. Ship to Customer
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How?
Mechanical Inspection
Physical Damage
Test by whatever means available
Electronic Ins ection
Light & Play Functional Tests
Fault Isolation
Diagnostic Testing Shorts, Opens, Functional, Parametric
Environmental
Repetition (Intermittent)
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Turn it on Power the Unit Talk to it
u omo ve ommun ca ons CAN/Class II/ISO9141/KW2000/GMLAN/ SAE J1939 Satisfy Security Requirements Establish the appropriate handshake to enable interaction
Create the automotive environment ie Connect it to appropriate inputs and outputs Simulate the necessary automotive events
Keep alive communications
Proper automotive messages and timing
unc ona er ca on Exercise the ECU
Operate and verify each function
Verify the ECU can handle the power and load requirements Verify the ECU can accept inputs from sensors, actuators, switches.
Verify Intermittent Faults Temperature and Thermal Shock Vibration
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Diagnose faults and determine if repairs are
possible
Automated Testing
Parametric Testing
Re lace Fault Com onents
Test & Verify Unit meets remanufacturersstandards of quality
It really works
It meets OEM specifications
u on e s e or s pmen or on o e nexphase.
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Configure Set vehicle option content: LS/SS/ST, Transmission
Type, Engine Type, KM, MK
Clear ECU Trouble Codes Program
Load/Flash ECU Software based on destinationvehicle
Update Software EE Flash Memory Odometer Settings Usage (Hour Meter) Set part number
Calibrate Gauges Sensors: Mass Airflow, Wheel Speed
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Functions Required
g ay Power
Communications CAN Class II ISO 9141 . Protocols, ie SAE 1939, GMLAN, Common Architecture
Functional & Diagnostic Testing Exercise the ECU
Verify the ECU can handle the power and load requirements Verify the ECU can accept inputs from sensors, actuators, switches.
Verify ECU Meets your standard or OEMs standardsunc ona er ca on
Parametric Verification
Configuration/Calibration/Programming
Maintain History of Part and Part Numbers Results of testing
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Remanufacturing ECU Test Equipment
u r Affordable
mp e Light & Play
Ease of Use (operation and training)
Handle multiple ECUs across product lines and model years Support for cataloging thousands of parts
Automated and Manual Test to diagnose and verify Capable of Validating OEM Specifications Re-flash Pro rammin Calibration Automotive Level Power and I/O Small floor or workbench footprint
Upgradeable Serviceable over many years Reliable
Low cost, on site certification and diagnostic capability
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Demonstration will Test and
Panel Cluster Product Selection
Test Sequence is an OperatorInteractive Session to Verify: Telltale Operation Illumination Functionality for Each
Gauge utomat c er cat on o
Communications Cluster Response
Programming/Configuration/Ca
Capable of FlashingSoftware
Setting Odometercontent
Calibrating of Gauges Clearing of Trouble Codes
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I PC V i s i o n
P TM 5 4 0
T e st So l u t i o n ABS Lo a d B o x
T r u ck B o d y Com p u t e r HUD
P TM B o a r d P r o d u c t s
P o r t a b l e
P TM 8 2 0
T e l e m a t i c s
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PTM 540 Universal Test Controller
u - y Universal IPC/ECU Audit, End ECU Type Products Tested
o L ne an erv ce TestController
ABS 285
Antenna Modules 22
BCM 356
DIC 24
DRA 324
HUD 51
IPC 3,250
HD IPC 1,129
PODS 62
Radio 65
Total 5,927
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Equipment Located in Ann Arbor Michigan
PTM540 PTM877 IPC Vision System
Internet Remote Access to the PTM540 Demonstration will Test and Calibrate a GMT
360 Instrument Panel Cluster The Cluster is loaded into the Vision
S stem and alread in the down osition Test Sequence
Automatically detect the product type Power On Wait until Cluster is at the proper vehicle
mounting angle Turn on the vision system. Validate all signal and message
communications
Clear Calibrations Validate illumination Validate Telltales for color and intensity Locate all gauges, needles and calibration
oints Position the needles at the calibration
points Verify the calibration at each point for
each gauge is successful
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for testing ECUs providing:
without requiring different equipment for
.
Verification the remanufactured product
Functional Capability Matches End of Line
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Hardware Designed for Automotive
Realistic Accurate Test Environments
Reusable & Redeployable Hardware and
Support for the Long Haul
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