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Welcome

Developing Testing Technologies for Remanufacturing Automotivefor Remanufacturing Automotive Systems Communicating via CAN Bus

P f R lf St i hilProf. Rolf SteinhilperDr. Stefan Freiberger

Matthias AlbrechtMatthias AlbrechtJosef Käufl

Constantin Brückner

November 13, 2009 Bayreuth University

Germany

ChairManufacturing and RemanufacturingTechnology

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Table of Contents

Introduction

Trend Towards Mechatronics and Electronics

CAN‐Reman Research Project

Example: Electro Hydraulic Power Steering (EHPS)

Conclusion


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City of Bayreuth

Europe • Population: 75,000

• World‐renowned fori h d i l

GermanyRichard Wagner Festival

• Half way betweenMunich & Berlin

Bayreuth

Bayreuth

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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)

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Chair Manufacturing and Remanufacturing Technology

AssemblyDesign for Disassembly Remanufacturing

Plant Layout O ti i ti

Disassemblyy

Optimization

Cleaning

Reconditioning

Testing Cleaning TechnologiesTesting Cleaning Technologies for Turbo Chargersand Diesel Particle Filters

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CNC Surface BrushingTesting and Diagnosis Technologies for Automotive Mechatronics


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Table of Contents

Introduction




Conclusion


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Remanufacturing Products and Parts – Now and in the Future

Trend towardsMechatronics/

Electronics

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Remanufacturing Process Steps – Changes for Mechatronics

Important additional Step for Remanufacturing of Car Mechatronic SystemsQuality Assurance of Car Mechatronic SystemsQuality 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/orReplenishment by new Parts

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Final Testing

6. Product Reassembly


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Table of Contents

Introduction




Conclusion


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CAN-Reman Research Project

Testing and Diagnosis Technologies Development for Car Mechatronic and Electronic Remanufacturing

Project consortium

Project aimsUnderstanding the functionality of data

communication in vehicles (CAN Bus).

Operation and testing of mechatronic and electronicOperation 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

10Picture: Workshop„Hands-on“: 5th October 2009 Picture: Workshop „Theory“: 5th October 2009


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Table of Contents

Introduction




Conclusion


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CAN Reman Project StructureAcquisition 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 generatorCAN Bus Analysis

Failure Memory Analysis (CAN)

• Possible failures• Erasing the memory

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a signal generatorCAN Bus Analysis• Relevant IDs• CAN messages• Reduction of data

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Reference Systems(TRW EHPS, test vehicle)test vehicle)

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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 VW‘s Polo, model year 2002Source: Volkswagen AG (2001) SSP 263 – Der Polo Modelljahr 2002, p.40, Wolfsburg


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Analysis of the Electro-Hydraulic Power Steering (EHPS) Pump1 1 x E le c tro n ic h o u s in g 1 1 0 x 1 0 1 x 1 4 7 A lu m in iu m2 1 x R o to r Ø 9 5 x 1 1 7 S te e l3 1 x M e ta ll R in g c a . 4 0 x 3 0 x 5 S te e l4 1 x S e a lin g g a s k e t 1 4 x 8 x 1 S te e l5 1 x C o il w ith e le c tro n ic c irc u it 1 1 5 x 1 2 8 x 9 7 n .a .6 4 x T o rx s c re w s M 3 x 1 2 S te e l7 2 x B ra c k e ts c a 3 0 x 1 5 S te e l

• Power Consumption: 2-3A (idle) up to 100A (load case)

• Revolution speed: 1100 rpm 7 2 x B ra c k e ts c a . 3 0 x 1 5 S te e l8 1 x P u m p b a s is 1 3 0 x 1 9 2 x 1 3 3 A lu m in iu m9 1 x R in g 1 4 x 8 x 1 S te e l

1 0 1 x C irc lip 8 x 1 0 S te e l1 1 1 x C o u p lin g 1 1 x 1 4 S te e l1 2 1 x P u m p c a b (b e lo w ) w ith s e a lin g g a s k e t 7 3 x 9 1 x 1 9 A lu m in iu m1 3 1 x P u m p d e v ic e (w ith ? ? ? ? 1 7 x 3 2 x 5 8 S te e l/ A lu m in iu m

(idle), 3400-4000rpm (load case)

• CAN IDs: 3D0 (status), 5DE (1 4 1 x P u m p b o d y 6 8 x 9 1 x 4 6 A lu m in iu m1 5 4 x A lle n s c re w M 8 x 6 8 S te e l

1 6 1 xP u m p c a b (a b o ve ) w ith s e a lin g g a s k e t+p re s s u re c o n tro l va lve 2 x 9 1 x 6 8 A lu m in iu m

1 7 1 x S e a lin g g a s k e t 1 1 0 A lu m in iu m1 8 1 x C la m p 1 1 0 A lu m in iu m1 9 1 O il t k 1 2 8 1 1 0 P A 6 6

(failure memory)

• Diagnostics: Transport protocol TP1.6 and KW1281

1 9 1 x O il ta n k 1 2 8 x 1 1 0 P A 6 6

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185

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2 7 10

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1396 1

4193 4 1

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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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a signal generator

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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 Fakultät für 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%)

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◄ Source: Volkswagen AG (2001) SSP 259 – Die Elektro-Hydraulische Servolenkung, p.8, Wolfsburg


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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

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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)

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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

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Development of a test bench









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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

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• 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




Conclusion


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Remanufacturing of Automotive Mechatronics

Remanu-CAN Bus Know-how

Remanu-facturingTechnolo-

gies

Diagnostics

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Tools for Remanufacturing of Automotive Mechatronic and Electronic Parts


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TTHANKHANK YYOUOU

… for your attention!

Matthias AlbrechtDr. Stefan Freiberger

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