OBD & NO x anti-tampering system architecture experiences & lessons learned

Transcription

1 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber 2014 ingenius OBD & NO x anti-tampering system architecture experiences & lessns learned BRACE Autmtive Marcel Rmijn Cmpetences crdinatr OBD & Emissin specialist

2 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Intrductin Often verlked are cnsequences f OBD and NO x anti-tampering legislatins t system architectures. Als hw unclear bundaries f the OBD system can generate prblems. Even mre valid fr heavy-duty n- and ff-highway. This presentatin aims t discuss these ptential prblems and the lessns t learned. Agenda: Vehicle Diagnstics verview Legislatin requirements impacting system architecture Diagnstic Master & Slave Use f ff-the-shelf smart sensrs & actuatrs frm suppliers Architecture cnsequences n legislatin cmpliance, required service infrmatin & emissins warranty Cncluding

3 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Vehicle Diagnstics verview Engine OBD (emissins) NO x inducements (EGAS) Functinal Safety Safety (e.g. fire risk) Driver assistence systems Functinal Safety Cmfrt systems Functinal Safety Transmissin OBD (emissins) Functinal Safety Brakes & Vehicle dynamics Functinal Safety Supplier t Vehicle OEM OEM is the respnsible crdinatr

4 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Vehicle Diagnstics verview Engine (by Engine OEM) OBD (emissins) NO x inducements (EGAS) Functinal Safety Safety (e.g. fire risk) Driver assistence systems Functinal Safety Cmfrt systems Functinal Safety Wrk applicatin (by Bdybuilder) Functinal Safety Transmissin (by supplier) Functinal Safety Brakes & Vehicle dynamics (by supplier) Functinal Safety Engine OEM & suppliers t Vehicle OEM t Bdybuilder Respnsible crdinatr?

5 Engine OEM & suppliers t Machine OEM Respnsible crdinatr? CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Vehicle Diagnstics verview Engine (by Engine OEM) OBD (emissins)? NO x inducements (EGAS) Functinal Safety Safety (e.g. fire risk) Cmfrt systems (by supplier) Functinal Safety Transmissin (by supplier) Functinal Safety Wrk applicatin Functinal Safety Driver assistence systems Functinal Safety Brakes & Vehicle dynamics (by supplier) Functinal Safety

6 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Legislatin requirements impacting system architecture Cncept f OBD & Emissins dmain Cncept t clarify the legal requirements Legislatin requirements can define the dmain Engine & Aftertreatment are always in An engine-dyn certificatin means transmissin is nt part f the dmain Hybrids are a difficult exemptin Special dmains, respnsibilites & certificatin prcedures fr Hybrids OBD & NO x warning system may be part f dmain Engine Driver interface (warnings) Transmissin Aftertreatment

7 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Legislatin requirements impacting system architecture Cncept f OBD & Emissins dmain US legislatin is very strict, while EU & thers nly s-s Any input t an OBD diagnstic = OBD & Emissins dmain E.g. switch ff Misfire diagnstic with lw fuel tank level r when Tractin Cntrl (via CAN) requests trque limitatin Any input t Emissins cntrls = OBD & Emissins dmain E.g. adapt EGR rate n Ambient temperature r the vehicle air pressure system as actuating medium fr Urea injectr Any system/cmpnent pssibly impacting emissins r OBD = OBD & Emissins dmain Signals t dmain X Dmain X Cmmands frm dmain E.g. Arctic Start Ether Supprt System, Wait-t-Start r Glw-plug light Systems, Start-Stp, Cling Systems, Driver mdes (ECO, Sprt), Cruise Cntrls Arctic Ether start

8 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Legislatin requirements impacting system architecture When inside the OBD & Emissins dmain Full-blwn OBD mnitring n sensr signals E.g. Electrical, Ranges, Plausibility, CAN-bus Full-blwn OBD mnitring n actuatrs & cmmands E.g. Electrical, Cmmands Respnse (whle actuatr system), CAN-bus Pssibility f being a DECECU (Diagnstic r Emissin Critical ECU) E.g. ECU OBD mnitring (Prcessr, Memry, Supply Vltage), Supprt CAL-ID (SW and Cal. part number) & CVN (SW and Cal. verificatin calculatin) Signals t dmain X Dmain X Cmmands frm dmain

9 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Diagnstic Masters & Slaves Many cntrl units pssibly in OBD & Emissins dmain Shuld they all cmmunicate individually t OBD Scantl? Shuld they all keep their wn strage f faultcdes and related infrmatin? Ambient air T ABS Vehicle speed Driver interface Glw plug cntrl Cling fan PM sensr Aftertreatment ECU Engine ECU EGR valve Urea pump NH3 sensr VGT actuatr OBD Scantl NOx sensr Swirl valves

10 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Diagnstic Masters & Slaves Typically ne r tw Diagnstic Masters are assigned Respnsible fr all fault cde strages -N synchrnizatin needed fr drive cycle definitins start/end & ther cycles -Prevent stack-up f fault cdes by the same prblem surce -Easy t allcate system verall diagnstics that mnitr ver several ECU s functins Supprts all scan tl cmmunicatin Smart gateway Experience: ~80 CAN messages ttal fr SAE J1939 scantl E.g. Cllects, stres, and updates CAL-ID/CVN s, Smart gateway fr Mde6 OBD, grups similar diagnstics under ne mnitr, aligns and cmbines all inf fr Readiness and Mnitr status, and aligns EI-AECD cunters with NTE area reprting Respnsible fr cmmands t driver interface Requires lts f interface agreements; sme f which d nt fit in with current standards Requires OBD expertise & preferably develp this nly nce!

11 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Diagnstic Masters & Slaves Placement f diagnstics based n diagnstic levels and infrmatin need System interpretatin f sensr value Envirnment in which the sensr measures Electrical circuit f the cmpnent System Plausibility Range Electrical Des the whle system act as it shuld? Des the value make any sense? Exceeding nrmal measurement range; in unit f the sensr Shrt/Open circuits; usually all the Vlt, Amps, Ohms things Every diagnstic needs infrmatin The mnitred value and enabling cnditins Lk at the surce f the infrmatin N pint in sending engine speed data t a NO x sensr, rules ut the pssibility f diagnstics that require engine speed based enabling t be funded in NO x sensr.

12 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Use f ff-the-shelf smart sensrs/actuatrs frm suppliers Typical Heavy-Duty Diesels = large amunt ff-the-shelf parts Ecnmy-f-scales cst reductin reasns Makes diagnstic respnsibility a multi-cmpany task Many (sub)suppliers have little knwledge abut i.e. OBD & NO x anti-tampering Purchasing cntracts ften nt technically deep enugh Lack f imprtant details r even requesting nly OBD cmpliance as a generic term Makes all the ingredients fr a disastrus develpment prject!

13 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Use f ff-the-shelf smart sensrs/actuatrs frm suppliers False PASS scenari with ff-the-shelf part based n real-life experience Smart valve (i.e. EGR) based n stepper-mtr & butterfly valve; internally diagnsed fr stuck butterfly valve by means f internal cntrl errr CAN cmmunicatin cnsisted f 1 bit per internal fault. If bit = FALSE; Then PASS status t fault cde strage & scan tl inf If bit = TRUE; Then FAIL status set t fault cde strage & scan tl inf Nw ask yurselves; what is a scenari f a stuck valve? Say the valve can nt mve t mre than 50% pening due t blckage Valve wrks fine belw 50% pening

14 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Use f ff-the-shelf smart sensrs/actuatrs frm suppliers Let s imagine hw des the diagnstic react? FALSE PASS! Engine Start / Running PASS CAN bit = FALSE Yes Set pint< 50% N CAN bit = TRUE FAIL First at start setpint = 0; s PASS is set Later during engine running setpint = >50%; s FAIL is set Fault is nw self-healed at every engine start r when setpint is <50%

15 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Use f ff-the-shelf smart sensrs/actuatrs frm suppliers False PASS issues with ff-the-shelf parts; a real life experience cnt d: Tw slutins investigated: 1) Blame the new-t-obd (sub)supplier: Mdify the internal diagnstic by adding enabling cnditins 2) Let the OBD engineers fix it: Dn t frward directly the (sub)suppliers internal status t fault handling With 1, the supplier needed t wait fr diagnsing unless the setpint was at higher level What t d with the 1 bit fault reprting in CAN? When nt TRUE is that a PASS r just a Dn t knw yet? With 2, make the OBD master handle the waiting fr diagnsing until a relevant setpint In the meantime ignre whatever the smart valve was sending in fault reprting This experience has cme again and again in many situatins and systems Even utside OBD such as Safety related diagnstics

16 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Use f ff-the-shelf smart sensrs/actuatrs frm suppliers DECECU (Diagnstic r Emissin Critical ECU) in USA: Check up-t-date legislatin bundary between cmpnent and ECU Typical example: mre then 2 Cmpnents (e.g. Sensrs) DECECU Example: Smart valve Cmpnents: Stepper mtr (actuatr), psitin sensr, and PCB electrical circuits temperature sensr (verheat prtectin) Usually nly first tw used; thus nt a DECECU Hwever, PCB temperature sensr can als be used by OBD master in assisting e.g. Engine Clant Temperature plausibility check Nw all three are used and therefre DECECU Special Nte: The same cmpnent can be a DECECU in ne applicatin and nt be a DECECU in anther applicatin Makes fr interesting discussins between OEMs, suppliers and sub-suppliers!

17 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Architecture cnsequences n legislatin cmpliance, required service infrmatin, and emissins warranty What are the cnsequences if we end up with a cmpliancy disaster? False PASS r n-detectins give rise t prblems with legislatr in USA Many f these are fund in required tests n series-prductin vehicles either perfrmed by OEM r perfrmed by legislatr False FAIL r nn-existent failures give rise t prblems with custmers Legislatr is unhappy t because it generates a bad image regarding required OBD & NO x anti-tampering systems Pssible cnsequences 1. (Frced) recall & warranty csts 2. Expsure in news; (i.e. r 3. Pssibly fines

18 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Architecture cnsequences n legislatin cmpliance, required service infrmatin, and emissins warranty Emissins related warranty; an USA thing: Fr items in the Emissins & OBD dmain an extended warranty is required Can last up t 10 years and depending n vehicle type varies frm km t km All warranty repairs must be reprted t legislatr; regardless f repairer When a certain % f vehicles has gtten the same warranty repair frced recall A DECECU has a lnger warranty term than a cmpnent Thus dmain creatin can be driven by ptential warranty csts and recalls Many OEMs have a list f n-g signals as the assciated sensr wuld be t expensive in warranty claims Same cmpnent in a different applicatin can make the difference f a 3 years B10 vs. a 10 year B1 reliability demand Cmpnents that cannt cmply may becme maintenance items (e.g. NO x sensrs) Set a maintenance term n when t replace mst f the cmpnents befre they are brken

19 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Architecture cnsequences n legislatin cmpliance, required service infrmatin, and emissins warranty Infrmatin exchange A lt f infrmatin must be disclsed abut the wrkings f Emissins system and OBD During type-apprval applicatin and during the vehicle lifetime n a publicly available Service Infrmatin website Includes als inf frm the ff-the-shelf cmpnents internal wrkings Again; great fun in discussins between OEMs, suppliers and sub-suppliers Sme examples f the public available infrmatin: Detrit Diesel: Frd (incl. Heavy-duty): General Mtrs:

20 CTI 3rd Internatinal Cnference Heavy-Duty Diesel Diagnstics 9th Octber ingenius Cncluding OBD, NO x anti-tampering & ther diagnstics are always challenging Usage in Heavy-duty dmain adds mre challenges Understanding respnsibilities thrughut the vehicle/machine is key Create bundaries with clear and limited I/O interfaces Just surcing cmpnents already requires fcus n many items unknwn t many utsiders Things that seem nt imprtant r were never imprtant befre can have the biggest financial impact Knwledgeable (sub)suppliers can be f great help (Sub)suppliers that are unaware can hwever create a nightmare scenari (Sub)suppliers need t be prepared t see very different demands f their prducts depending n applicatin

21 ingenius Questins?