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Diagnostics Development for a Series Production Dual Clutch Transmission
Neil Robson, GCE, Changan UK R&D Centre Ltd
Vector UK Conference 2015/06/10
One of largest automotive companies in China. Largest by “own brand” sales.
Top Four China
Automotive
Industry Groups
Data source:“ The Automobile Industry Restructuring and Revitalization Plan”
Changan Automobile Co Ltd
Changan is affiliated to China South Industries Group
Corporation. It has existing assets 68 billion yuan, nearly
50,000 employees worldwide.
0.0
0.5
1.0
1.5
2.0
2.5
3.0
1980 1985 1990 1995 2000 2005 2010 2015 2020
Mill
ion
ve
hic
les
Year
Vehicle sales volumes
During the ‘Eleventh five-year plan’, Changan’s sales increased 3.78 times, income 5.13 times,
and profit 5.14 times, which created the highest development speed in China’s Auto industry.
In just 28 years, the accumulative total sales volume breaks through 10 million vehicles, which marks the fastest
automobile enterprises which breaks through ten million. In 2014 sales exceeded 2.6 million. 2015 on target for > 3
million.
Production and sales Scale
Changan Sales Volumes
Alsvin V5
RAETON
Benni
Main products(Passenger Car)
EADO CS35(SUV)
CS75 (SUV)
Eado XT
Nottingham, UK
Power Train
Establishment of global R&D layout of “9 locations in 5 countries”
Chongqing
Study on
comprehensive
technology of
automobile
Turin, Italy
Styling,
bodywork
Detroit, USA
Chassis
technology
Beijing
New energy
automotive
technology
Shanghai
Vehicle integration
Yokohama, Japan
Interior and exterior
trimming, automobile
engineering
Haerbin
Vehicle
development
Jiangxi
Power technology
Changan R&D Network
Changan UK is the core base for the whole Changan Group in the area of Powertrain (Engine + Transmission ) Systems. Changan UK is:• Research and Development Centre for advanced powertrain technologies.• Powertrain Engineering Centre.
Changan UK Overview
VISION•To become a World Class powertrain R&D centre, a promoter and practitioner of green powertrain technologies
MISSION• To design and develop high quality, high performance powertrains to support
Changan’s global requirements.• To develop a technology roadmap and expertise for Changan Powertrain.• To create an environment and opportunities for staff development
UK Director
Advanced Powertrain
Engines TransmissionsPowertrain Control &
ElectronicsOperations
HR Finance & IT
Project Management
CAUK HQ
MIRA
CAUK Fen End
Changan UK Organisation
• Use world class suppliers to enable a robust foundation
– HCU
– Clutches
– TCU
– Sensors
– Bearing
– Oil
– Synchronisers
• Internally engineered and sourced components
– Casings
– Gears&Shafts
– Fork System
– Park Brake
– Flywheel
– Pump
– Filters
– Differential
The New 7 Speed DCT from Changan UK R&D Ltd
Diagnostics System Boundary
Phase 1: Diagnostics capability analysis
• Assessment of multiple suppliers to help define system diagnostics coverage• Bosch Diagnostics Services chosen as best supplier to support work• Integrated into overall System Engineering activities
© Robert Bosch GmbH
© Robert Bosch GmbH
Au
xilia
rie
s
DPA Results - Overview
No Component name Diagnostic
capability
(Current/Future)
Exchangeable Number of
Failures
1 TCU (Transmission Control Unit) 68 / 72 Yes 27
2 Dual Clutch Module N/A Yes N/A
3 HCU (Hydraulics Control Unit) (59 / 59)* No (6)
4 Bulk Oil Temperature Sensor 11,7 / 71,2 Yes 7
5 Input Shaft Speed Sensor 93 / 93 Yes 5
6 Output Shaft Speed Sensor 80 / 80 Yes 6
7 PRND Sensor 98 / 98 Yes 4
8 Shift forks 40 / 100 No 1
9 Transmission Oil (0 / 80)* Yes 1
10 Electrical Harness (77 / 77)* Yes 18
11 Earth Strap and Fuse (80 / 80)* No 1
12 Transmission Oil Pump 0 / 100 No 2
14 Shift Lever 81 / 81 Yes 3
15 TIP Switches 28 / 78 No 4
16 Auto / Manual Switch 33 / 80 No 4
17 Ignition Switch 80 / 80 Yes 2
Total: 41 / 76 10 91
Ma
in c
om
po
ne
nts
:
Tra
ns
mis
sio
n
10 possible smallest
exchangeable components
identified
91 Failure modes total
159 DTCs currently available
within transmission control
system (Suggestion by Conti)
22 Failures cause no fault
memory entry (DTC)
16 Failures with current
diagnostic gaps*Items in brackets done in offline postprocessing
Diagnostic capability of system
DPA Results - Summary
Pre-analysis Post-analysis
• Target coverage > 70%
• No part on-cost to achieve Post-analysis level
Phase 2: Diagnostics Specification and V & V Plan
• Assessment of multiple suppliers to help define:• detailed diagnostics system specification to drive software design and
implementation activities.• detailed plan to verify and validate diagnostics system implementation and
requirements• Vector chosen as best supplier to support work
Vector diagnostics specification and validation process
Changan diagnostics specification and validation process
Diagnostics input from
System Requirements
Engineering, Functional
safety, DFMEA, DPA
Translation from system
specification => Manual
TCU software
implementation
AVL
Changan
+ HIL testing (dSPACE
Automation Desk)
INCA
INCA
Diagnostics Specification Results - Overview
• Development of a CANdelaStudio document containing all protocol services and data
Diagnostics Specification Results - Overview
• Development of specifications for behavioural aspects that falls outside the scope of the CANdelaStudio document
Diagnostics Specification Results - Overview
• Generation of data for consumption in other systems (ODX and Cradle)
• Traceability to upstream systems (requirements engineering)
• Linkage to DFMEA
• Export for downstream usage
• Planning of validation and verification activities
• Alignment with overall DVP
Further Work - Vector Indigo Demonstration
The purpose of the exercise was to demonstrate the capability of performing UDS
communications to a worldwide remote application.
The test was to demonstrate UDS interrogation of the DCT TCU located at Changan HQ
Chongqing from Changan UK Fen End. The Vector Indigo Tool Suite facilitated the
demonstration.
Changan UK
Vector Indigo
Changan UK
Wi-Fi
Vector Germany
Remote Server
China Internet
Server
Changan China
Indigo Remote Access
Vehicle UDS
Connection to
TCU
Conclusions
• Initial analysis of diagnostics coverage was highly valuable– Weakness in system requirements engineering uncovered early– Helped to focus downstream work
• Selection of right supplier(s) critical to project success• Using well proven diagnostics specification process and toolset minimised project
risk• Tools help but process and people capability need to be the foundation
• Next Steps:
• Fully integrate into System Engineering process• Investigate OTX