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Diesel OBD Oct 2010 Training Presentation_Final.pdf

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DIESEL OBD OCT 2010 TRAINING PRESENTATION_FINAL
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Diesel OBD Calibration Overview PCCN Training 26/10/10 Page 1 Diesel On Board Diagnostics Calibration Overview Presentation Objectives: ? To provide a basic overview of what Diesel OBD is and the feature team R no.of drive cycles warm-up cycles Monitor readiness IUPR Healing Error Classes ? OBD – Hardware / Systems protection - MIKE ? Exhaust overheat detection ? Maximum engine speed limitation ? Rundry prevention ? ‘Dependability’ - Torque Monitoring Concepts ? Revierw and add ? OBD – Service Information - MIKE Examples Obligation to assist in fault resolution Block exemption is being removed so that Non-EOBD diagnostics are available through generic tools, and Non-ford dealersDiesel OBD Calibration Overview PCCN Training 26/10/10 Page 13 EOBD Legislation ? MIL use mandatory for faults that result in emissions above EOBD thresholds ? Ford policy of using MIL for “Gross Emitter” uses 2x base emissions as guide tbd 13.5 140 140 1500 St6 EOBD 6x10 11 5 170 80 500 St6 TA 50 540 320 1900 St5 EOBD 5 230 180 500 St5 TA Pn PM THC+NOx NOx NMHC CO all in mg/km except Pn ? Stage 6 EOBD thresholds are proposals (M-class figures shown). Interim (incentive) thresholds published are not as low as full Stage 6. ? EOBD Pn requirement expected to be sufficiently low to make soot sensor necessary. ? Determination of MIL faults done by carrying out emissions tests with faults inserted on EMIT rolls. Diesel OBD Calibration Overview PCCN Training 26/10/10 Page 14 Emissions Progression in Europe Reduction in EU Regulated Emissions 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 4 5 6 7 EU Emissions Stage x Proportional Change (EU4 = 1) TA NOx OBD NOx TA Pm OBD PmDiesel OBD Calibration Overview PCCN Training 26/10/10 Page 15 Availability of Diagnostic Information ? Certain information must be available to anyone with an OBD tool. ? Full diagnostic information available to Ford IDS system. Details contained in Part-2 specification. ? Data available to a generic scantool required by legislation and ISO/SAE requirements. Reference guide available for EU diesel apps. ? Mode 1: Live data – current values for items such as engine speed ? Mode 2: Freeze Frame data for stored faults ? Mode 3: “Confirmed” DTC(s) that caused MIL to be on ? Mode 4: Clear error memory ? Mode 7: “Pending” MIL relevant DTCs that haven’t yet turned the MIL on, or after healing and MIL off ? Mode 9: Vehicle data such as VIN, Cal ID, IUPR ? Mode 1 includes the status of the emissions monitoring system and reports the “Readiness” of groups of faults in Fuel, EGR, Boost, DPF and CCM. ? MIL on/off and fault erasing done by counters of Driving Cycles or Warm-Up CyclesDiesel OBD Calibration Overview PCCN Training 26/10/10 Page 16 Some Common Terms ? Readiness All non-electrical circuit checks that are capable of lighting the MIL must be capable of testing during the NEDC cycle. Systems must show all monitors tested unless a relevant fault is present. Status cleared when DTCs cleared. A Readiness test involves driving a suitable cycle to prove that all monitors are tested (monitor completion). ? Pending / Confirmed DTC Almost all MIL faults will not light the lamp until the third consecutive driving cycle where the fault occurs. If such a fault occurs, its status is Pending (and visible in generic Mode 7) at all times that the MIL is not lit. If the MIL is lit, it means the fault has occurred the required number of times to become Confirmed. Non-MIL faults and faults that light the lamp on the first occurrence do not pass through the Pending state and are Confirmed on first occurrence. ? Driving / Warm-Up Cycles A driving cycle is defined as a full key cycle that includes a period of engine running long enough to run a monitor. The MIL turns on and off based on the test results from three consecutive driving cycles. A warm-up cycle is defined as a cycle where the engine temperature rises 22 o C since engine start and reaches 70 o C. A healed MIL fault can be erased from error memory if the fault does not reoccur for 40 warm-up cycles.Diesel OBD Calibration Overview PCCN Training 26/10/10 Page 17 Bosch Diagnostic System Manager - FDEC ? Detection of the error state is done within the component or system function part of software. ? Error state is debounced before fault state is confirmed. ? Confirmed fault is stored in error memory. Warning lights and reactions to faults are triggered on confirmation of the fault. ? Error states are healed in a similar way to the setting of faults in that the error condition is reported as no longer present by the function, and that change of state is debounced before the condition is confirmed as healed. Reactions to the fault are released upon healing except a torque limitation.   Diesel OBD Calibration Overview PCCN Training 26/10/10 Page 18 Monitoring and Reactions ? Component Monitoring ? Signal Range Check (SRC) monitors circuit continuity ? Gradient Check monitors intermittent circuit ? Physical Range Check monitors for extreme conditions within range ? Plausibility Check confirms validity of sensor by comparing to other parts of the system when conditions are suitable. ? Functional Monitoring ? Inner and outer closed loop controller errors ? System status monitoring e.g. DPF overload, Exhaust over-temperature, Low fuel run-dry prevention ? Reactions ? Intended to stop secondary faults from being set ? Stop systems from running in uncontrolled manner ? Reduced power modes protect engine from more serious failures. ? Forced engine shutdown as last resortDiesel OBD Calibration Overview PCCN Training 26/10/10 Page 19 FMEMs (Failure Modes Effects Management) ? Customer observable Reactions ? MIL (Malfunction Indicator Lamp) ? AKA ‘Check Engine Light’, which is an indicator of a malfunction of the PCM controlled engine management system that will/could have an impact EOBD emission thresholds. This stand-alone lamp is legislated and must be tested on KOEO. ? PCL (Powertrain Check Lamp) ? This warning light is to indicate serious trouble with the engine, i.e. low oil pressure, overheating, charging system problem, etc… ? Reduced Torque ? The engine performance is restricted artificially to prevent potential damage to the powertrain system. This can be done by limiting the maximum torque or engine speed. ? Engine Off ? An ECU managed reaction which is triggered for customer symptoms which are deemed safety critical and decided based on corporate policy. ? SLOWE ? Specific reaction for reducing acceleration response once redundant signal is lost. ? Limp Home (High Idle) ? Fixed engine speed to allow for limited availability. Usually scheduled if torque delivery is compromised. ? Function and monitor inhibits ? EGR off ? An example of when the MIL must be lit as this reaction will have an impact on the tailpipe emission. ? DPF regeneration off ? If a component or factor of the system could influence or compromise the regeneration capability, the ECU scheduled inhibit will be prevent the supervisor from commencing this feature.Diesel OBD Calibration Overview PCCN Training 26/10/10 Page 20 When is a fault not a fault? ? Many error paths in the software can appear to be in an error state, but this can be due to other factors. Diagnostic software can differentiate between these and genuine error states. ? Monitor Entry and Disable Conditions ? Only permit a monitor to test and report an error when engine or vehicle conditions guarantee the result according to the truth table. For example, only monitor for a boost pressure control deviation when the system is in closed loop control. Entry conditions are monitor specific. ? Disable faults from being reported that may be due to system operating conditions. For example, CAN message errors are likely when battery voltage drops below 10V; declare a system voltage issue not a CAN problem. A global set of disable conditions are available to set up for every fault path, and include DPF in regen, high altitude, during engine start etc.Diesel OBD Calibration Overview PCCN Training 26/10/10 Page 21 Dependability ? Dependability is a balance between availability and safety. ? Safety related hardware monitors ? Functional responses to faults with accelerator, brake and clutch pedals ? Includes reduced functionality modes ? SLOWE – slow accelerator pedal response ? High idle – fixed engine speed for multiple failures ? Safety related software monitors ? Torque plausibility monitoring arbitrates all torque requests and compares these with engine output. This is Level 2 monitoring. ? Level 3 monitoring monitors the ECM chip functions e.g. NVM, ROM, RAM. ? Detected torque errors inhibit certain functionality e.g. ACC, FFL. ? Gross torque errors result in reduced torque/speed limitations.Diesel OBD Calibration Overview PCCN Training 26/10/10 Page 22 Diagnostic Development Process ? Overview of the tasks each OBD calibration engineer does for each phase of the GPDS (more later). X M VP R00 GDPS Process Logic Collect H/W Specs of Act & Sensors Collect vehicle interface info Software Analysis Define thresholds based on cal maturity Robustness testing with limit and aged components Software testing Vehicle development Plausibility diagnostic validation HIL Automation Full DVP Climatic / ETL testing Dependability PV testing Supplier VRTs & Dependability Transmittals Evidence Books Certification Fleet monitoring (including IUPR)Diesel OBD Calibration Overview PCCN Training 26/10/10 Page 23 DV Doc Design Verification Document ? Developed from first application available software. ? Provides test methods to check all monitors ? Documents DTC assignment ? Details behavior of strategy implementation ? Assignment of FMEMs ? Validation test for each monitor ? Provides an evidence tool for sign-off ? Process tracking tool for reporting ? Provides DTC list for Part 2 Specs ? Used as the basis for the OBD certification document for type approvalDiesel OBD Calibration Overview PCCN Training 26/10/10 Page 24 Workflow Process ? GPDS process work planner for diagnostics activities ? Aligned with the same gateways. ? Timings and resourced compatible with programme ? Includes a join-up effort between other groups, in Calibration, Software, T&D, Homoglation, Launch, Manufacturing and programme management ? Tasks described at working level by 'gets', 'dos' and 'gives' from an OBD development engineer's point-of-view. ? Case Study – Plausibility Monitoring Gets – What 'stuff/information' the engineer needs to perform the DV of this monitor, i.e. could be a faculty, vehicle, software or other team's calibration maturity. Dos – What the engineer actually does with the 'stuff/information', i.e. a description of the DV procedure to develop/sign-off this calibration feature. Gives – The output of the engineer's task and a deliverable to other user, i.e. a calibrated monitor to support a prototype build phase
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