2008 Testing Automotive Mechatronics

7/29/2019 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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Documents

2008 Testing Automotive Mechatronics