for Remanufacturing Automotive for Remanufacturing Automotive Systems Communicating via CAN Bus P f R lf St i hil Prof.RolfSteinhilper Dr.StefanFreiberger Matthias Albrecht MatthiasAlbrecht JosefKufl ConstantinBrckner November13,2009 BayreuthUniversity Germany Chair Manufacturing and Remanufacturing Technology UP Table of Contents Introduction TrendTowardsMechatronics andElectronics CANReman ResearchProject Example:ElectroHydraulicPowerSteering(EHPS) Conclusion Chair Manufacturing and Remanufacturing Technology UP City of Bayreuth Europe Population:75,000 Worldrenowned for i h d i l Germany RichardWagnerFestival Halfway between Munich &Berlin Bayreuth Bayreuth 2 Munich Images: maps.google.de Chair Manufacturing and Remanufacturing Technology UP 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) 3 Chair Manufacturing and Remanufacturing Technology UP Chair Manufacturing and Remanufacturing Technology Assembly Design for Disassembly Remanufacturing Plant Layout O ti i ti Disassembly y Optimization Cleaning Reconditioning Testing Cleaning Technologies Testing Cleaning Technologies for Turbo Chargers and Diesel Particle Filters 4 CNC Surface Brushing Testing and Diagnosis Technologies for Automotive Mechatronics Chair Manufacturing and Remanufacturing Technology UP Table of Contents Introduction TrendTowardsMechatronics andElectronics CANReman ResearchProject Example:ElectroHydraulicPowerSteering(EHPS) Conclusion Chair Manufacturing and Remanufacturing Technology UP Remanufacturing Products and Parts Now and in the Future Trend towards Mechatronics/ Electronics 6 Chair Manufacturing and Remanufacturing Technology UP Remanufacturing Process Steps Changes for Mechatronics Important additional Step for Remanufacturing of Car Mechatronic Systems Quality Assurance of Car Mechatronic Systems Quality 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/or Replenishment by new Parts 6 P d t R bl 7 Final Testing 6. Product Reassembly Chair Manufacturing and Remanufacturing Technology UP Table of Contents Introduction TrendTowardsMechatronics andElectronics CANReman ResearchProject Example:ElectroHydraulicPowerSteering(EHPS) Conclusion Chair Manufacturing and Remanufacturing Technology UP CAN-Reman Research Project Testing and Diagnosis Technologies Development for Car Mechatronic and Electronic Remanufacturing Project consortium Project aims Understanding the functionality of data communication in vehicles (CAN Bus). Operation and testing of mechatronic and electronic Operation and testing of mechatronic and electronic systems independent from the car (simulation of the vehicle by appropriate software). 9 Development of a test bench for electronic and mechatronic systems for remanufacturers. Chair Manufacturing and Remanufacturing Technology UP Partners CAN-Reman Picture: Kick-Off-Meeting: 31th March 2009 10 Picture: WorkshopHands-on: 5th October 2009 Picture: Workshop Theory: 5th October 2009 Chair Manufacturing and Remanufacturing Technology UP Table of Contents Introduction TrendTowardsMechatronics andElectronics CANReman ResearchProject Example:ElectroHydraulicPowerSteering(EHPS) Conclusion Chair Manufacturing and Remanufacturing Technology UP CAN Reman Project Structure Acquisition 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 generator CAN Bus Analysis Failure Memory Analysis (CAN) Possible failures Erasing the memory 12 a signal generator CAN Bus Analysis Relevant IDs CAN messages Reduction of data g y Chair Manufacturing and Remanufacturing Technology UP CAN Reman Project Structure Acquisition of Reference Systems (TRW EHPS, test vehicle) test vehicle) 13 Chair Manufacturing and Remanufacturing Technology UP 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 14 Interaction of the CAN controllers in VWs Polo, model year 2002 Source: Volkswagen AG (2001) SSP 263 Der Polo Modelljahr 2002, p.40, Wolfsburg Chair Manufacturing and Remanufacturing Technology UP CAN Reman Project Structure Acquisition of Reference Systems (TRW EHPS, test vehicle) test vehicle) Analysis of the Reference Systems Input (parameters) Output (parameters) 15 Chair Manufacturing and Remanufacturing Technology UP Analysis of the Electro-Hydraulic Power Steering (EHPS) Pump 1 1x Elec tronic housing 110x101x147 Alum inium 2 1x Rotor 95x117 Steel 3 1x Metall Ring ca. 40x30x5 Steel 4 1x Sealing gask et 14x8x1 Steel 5 1x Coil with electronic circuit 115x128x97 n.a. 6 4x T orx screws M3x12 Steel 7 2x Brack ets ca 30x15 Steel Power Consumption: 2-3A (idle) up to 100A (load case) Revolution speed: 1100 rpm 7 2x Brack ets ca. 30x15 Steel 8 1x Pum p bas is 130x192x133 Alum inium 9 1x Ring 14x8x1 Steel 10 1x Circlip 8x10 Steel 11 1x Coupling 11x14 Steel 12 1x Pum p cab (below) with sealing gas k et 73x91x19 Alum inium 13 1x Pum p device (with???? 17x32x58 Steel/ Alum inium (idle), 3400-4000rpm (load case) CAN IDs: 3D0 (status), 5DE ( 14 1x Pum p body 68x91x46 Alum inium 15 4x Allen screw M8x68 Steel 16 1x Pum p cab (above) with sealing gask et+ pressure c ontrol valve 2x91x68 Alum inium 17 1x Sealing gask et 110 Alum inium 18 1x Clam p 110 Alum inium 19 1 Oil t k 128 110 PA66 (failure memory) Diagnostics: Transport protocol TP1.6 and KW1281 19 1x Oil tank 128x110 PA66 16 1 8 1 8 5 1 7 1 5 1 6 2 7 1 0 1 2 1 3 9 6 1 4 1 9 3 4 1 1 Chair Manufacturing and Remanufacturing Technology UP CAN Reman Project Structure Acquisition of Reference Systems (TRW EHPS, test vehicle) test vehicle) Analysis of the Reference Systems Input (parameters) Output (parameters) Analysis of pump car interaction Wiring Involved controllers 17 Chair Manufacturing and Remanufacturing Technology UP 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 18 Source: Volkswagen AG (2001) SSP 259 Die Elektro-Hydraulische Servolenkung, p.8, Wolfsburg Chair Manufacturing and Remanufacturing Technology UP CAN Reman Project Structure Acquisition of Reference Systems (TRW EHPS, test vehicle) test vehicle) Analysis of the Reference Systems Input (parameters) Output (parameters) Analysis of pump car interaction Wiring Involved controllers Analysis of Sensors PWM Signal Simulation e.g. using a signal generator 19 a signal generator Chair Manufacturing and Remanufacturing Technology UP 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 Fakultt fr 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%) 20 Source: Volkswagen AG (2001) SSP 259 Die Elektro-Hydraulische Servolenkung, p.8, Wolfsburg Chair Manufacturing and Remanufacturing Technology UP CAN Reman Project Structure Acquisition of Reference Systems (TRW EHPS, test vehicle) test vehicle) Analysis of the Reference Systems Input (parameters) Output (parameters) Analysis of pump car interaction Wiring Involved controllers Analysis of Sensors PWM Signal Simulation e.g. using a signal generator CAN Bus Analysis 21 a signal generator CAN Bus Analysis Relevant IDs CAN messages Reduction of data Chair Manufacturing and Remanufacturing Technology UP 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 22 Chair Manufacturing and Remanufacturing Technology UP CAN Reman Project Structure Acquisition of Reference Systems (TRW EHPS, test vehicle) test vehicle) Analysis of the Reference Systems Input (parameters) Output (parameters) Analysis of pump car interaction Wiring Involved controllers Analysis of Sensors PWM Signal Simulation e.g. using a signal generator CAN Bus Analysis Failure Memory Analysis (CAN) Possible failures Erasing the memory 23 a signal generator CAN Bus Analysis Relevant IDs CAN messages Reduction of data g y Chair Manufacturing and Remanufacturing Technology UP 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) 24 Chair Manufacturing and Remanufacturing Technology UP CAN Reman Project Structure Acquisition of Reference Systems (TRW EHPS, test vehicle) test vehicle) Analysis of the Reference Systems Input (parameters) Output (parameters) 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 generator CAN Bus Analysis Failure Memory Analysis (CAN) Possible failures Erasing the memory 25 a signal generator CAN Bus Analysis Relevant IDs CAN messages Reduction of data g y Chair Manufacturing and Remanufacturing Technology UP 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 26 Chair Manufacturing and Remanufacturing Technology UP CAN Reman Project Structure Acquisition 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 generator CAN Bus Analysis Failure Memory Analysis (CAN) Possible failures Erasing the memory 27 a signal generator CAN Bus Analysis Relevant IDs CAN messages Reduction of data g y Chair Manufacturing and Remanufacturing Technology UP 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 28 Permanent monitoring of the operating condition Fully automated evaluation of the measurements Chair Manufacturing and Remanufacturing Technology UP 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) 29 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 Chair Manufacturing and Remanufacturing Technology UP Table of Contents Introduction TrendTowardsMechatronics andElectronics CANReman ResearchProject Example:ElectroHydraulicPowerSteering(EHPS) Conclusion Chair Manufacturing and Remanufacturing Technology UP Remanufacturing of Automotive Mechatronics Remanu- CAN Bus Know-how Remanu- facturing Technolo- gies Diagnostics g 31 Tools for Remanufacturing of Automotive Mechatronic and Electronic Parts Chair Manufacturing and Remanufacturing Technology UP TTHANK HANK YYOU OU foryourattention! MatthiasAlbrecht Dr.StefanFreiberger 32 Chair Manufacturing and Remanufacturing Technology UP