Engine Protection VW V3x Prop 02

7/23/2019 Engine Protection VW V3x Prop 02

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1 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt

Schedule plan

Proposal

Strategy

applied

Tests

ok?

VW

approved?

yes

yes

Dataset

no

no

Engine protection strategy NFB


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Main ConsiderationsEngine protection strategy NFB

This strategy was created in order to avoid engine / vehicle damage ;

Main target is never stop the vehicle by engine fault ( unless some special

cases );Decision to stop the vehicle will be taken by driver;

Fault memory will save all failure modes and also the current situations(10 environmental conditions);

In case of degradation the system will take warnings and protective actions( if necessary ) just after fault confirmation;

Major actions will be taken as progressive as possible;

Already existing cluster warnings will be kept in order to assure betterprotection ( cluster buzzer and indicators will work together with ECU actions );

This strategy was created by VW, IAV, Bosch and MWM working team;

Software calibration and system reactions on vehicle have been evaluatedsince first V10 SW version delivery Phase 2 and V20 on Insurance project.


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Environments conditionsEngine protection strategy NFB

fpsc_p_w Fuel pressure set point evss_v_filt_w Vehicle Speed

efps_p_w actual fuel pressure cane_p_boost_w Boost Pressure

fpc3_dc_reg_w Duty cycle of CP3 valve ects_t_w Engine Coolant Temperature

dinj_q_mi_w main quantity injection cane_r_load_w Engine % Load

fpm3_s_def_uc Type of fuel pressure monitoring defect fqsc_s_uc Engine Torque Mode

fpm3_s_prelimdef_uc Preliminary of fuel pressure monitoring defect

efps_s_def_uc Fuel pressure sensor defect

ects_s_def_uc Coolant sensor temperature defect

+ Engine Speed

+ Engine ECU hours

Actual Dataset DM4 - J1939

Below it is described an example with two configurations for a rail pressure

failure.

On the left side, it was applied for each failure an optimized environmentalcondition

On the right side, as described in J1939 for DM4, for all failure it will besaved always the same environmental condition.

MWM-I and IAV suggest to keep the optimized proposal for each failuredetection instead of standard values.


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New Features in Software V33Engine protection strategy NFB

Remote start/stop

Clutch protection function (not used)

CAN messages:

Engine hours, Fuel consumption, status of water in fuel and coolantempty level, status CC, engine brake, DM1, DM3 and DM4, status ofcabin locked and neutral switch, status of warning and stop lamps

Vehicle start moving in first or reverse gear only (not used)

HISP / FLIM steps

Water in fuel sensor

Coolant level sensor

Acceleration Pedal 2 Poti

Cruise Control

VALC Vehicle acceleration limit control


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Vehicle evaluationEngine protection strategy NFB

Vehicle even with higher degradation have to climb a maximal 12%

ramp; Major quantity of faults with only warning lamp activation ( withoutdegradation level )

Limp home mode ( degradation level 3 ) permits vehicle running to

a safe place. The only one failure that will shut off the engine is a high or a lowrail pressure.


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Failures distributionEngine protection strategy NFB

Total Possible Failures = 98

Applied Functions = 63

NO degradation level = 33 failures ( 52,2% )

APS , Battery, BPS(Sensor defect), BTS, Camshaft, CAN, Clutch,EEPROM, OTS, Power Supply System, Brake switch, Tachograph

Degradation level 1 = sensible power reduction = 7 failures ( 11,2 % )

Boost Pressure Controller, Coolant level and Oil pressure sensor (sensor

defect); water in fuel (below threshold), Exhaust Engine Brake, Crankshaft


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Failures distributionEngine protection strategy NFB

Degradation level 2 = medium power reduction = 10 failures (16%)

Boost pressure (above threshold), Injector capacitors, oiltemperature(120C), system start up test, solenoid valve.

Degradation level 3 = limp home mode = 12 failures ( 19 % )

Coolant temperature(above threshold(103C)), oil temperature(130C),coolant level (below threshold), fuel pressure sensor, CP3 valve, main realy,pressure deviation, pressure leakage detection, PRV, oil pressure belowthreshold, recovery, overrun monitoring

Degradation level 4 = Stop the engine = 1 failure (1,6 %)

High and low pressure


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Quantity[mg/stroke]

0

20

40

60

80

100

120

Engine speed [rpm]0 500 1000 1500 2000 2500 3000

System degradation levelEngine protection strategy NFB

Level 3

Level 4

NormalNormalNormal0Noreduction

4 shut off

3limp home

2mediumreduction

1 sensible

reduction

Leve

l

Railpressure

[MPa

]

Engi

nespeed

[rpm

]

Quan

tity

[mg/stroke9

6010000

60150070

80220070

140250090

Level 2

Level 1


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Degradation level strategy to switch over to next levelEngine protection strategy NFB

Level 1 to level 2 - with 3 different faults at level 1, the degradation is

increased to level 2

Level 2 to level 3 - with 2 different faults at level 2, the degradation isincreased to level 3

Level 3 to level 4 - to avoid engine shut off, this label is disable.


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Boost air pressureEngine protection strategy NFB

Sensor defect recognition

warning lamp and engine failure turns on

after 0 s no power reduction from SDML, and the engine performance is

reduced by smoke map

replacement value is 1500hPa, this may cause black smoke

Value above threshold

over 2950 hPa warning and engine failure lamp turns on

after 0s the system is degraded at level 2


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Boost pressure deviation

the BPCO function will be used for this protection

If there is a deviation above 1000hPa during 10 sec.,

the warning and engine failure lamp turns on

the system is degraded at level 1


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Plausibility check between boost and atmospherepressure

If the engine speed is below 800rpm (L.Idle + 50rpm) and the fuel

quantity is below 15mg/str, and there is a deviation above 100hPaduring 5 sec. between the boost and atmosphere pressure:

warning and engine failure lamps turn on

after 0 s no power reduction replacement value for boost pressure is 1500hPa

replacement value for air pressure is 820hPa



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Ambient Air PressureEngine protection strategy NFB


warning and engine failure lamp turn on

after 0 s no power reduction (Already checked on altitude tests)

replacement value is boost pressure value (below 1000 rpm and12mg/stroke)

if boost pressure sensor is also defective replacement value is 820hPa

Value above and below threshold

below 800hPaerror will be stored and no lamp (not possible)turns on

after 0 s power no power reduction from SDML

above 1200hPa warning lamp and engine failure turn on to detectsensor failure


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after 0 s no power reduction replacement value is-10 C


over125 C: stopand engine failure lamp turn on and after 0 sec.the system is degraded at level 2

over 130 C: stop and engine failure lamp turn on and after 0 sec.

the system is degraded at level 3

* The oil temperature is about 10C higher than coolant temperature.

* Highest oil temperature during cooling tests was 110C (VW Inf.)

Oil temperature sensorEngine protection strategy NFB


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after 0 s degradation level 1

replacement value is3000hPa

Value below threshold

If the oil pressure is below2500 hPaduring 5 secand the enginespeed is above 600rpm, the stop and engine failure lamp turn onand the system is degraded at level 3

Oil pressure sensorEngine protection strategy NFB


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stop and engine failure lamp turn on

after 0 s the engine is degraded at level 3.

pressure release valve will be opened

Maximal rail pressure limited to 80 MPa


For High andLow pressures detection, Stopand engine failure lampturn on and the engine is immediately shut off (level 4)

For Pos. and Neg. pressures deviation and Leakage detection, Stopand engine failure lamp turn and the engine is degraded at level 3(MPROP3,MPROP)

Fuel pressureEngine protection strategy NFB


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Acceleration pedalEngine protection strategy NFB



low idle speed is set to 1100 rpm(limp home mode)


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after 0 s degradation level 1

replacement value is 10 C to ensure coldstart

Coolant temperature sensorEngine protection strategy NFB


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0

20

40

60

80

100

95 100 105 110 115 120

Coolant Temperature (C)

Powerreduction(%)

1- over 103C the system is degraded at level 1, the warning and engine failure lamp turn on,starts a linear power reduction with FLIM curve at 20%, and the failure will be saved in the

memory.2- over 108 C stop lampturns on immediately, the system is degraded at level 3 (45% of power

reduction), and the failure will be saved in the memory. The L.U. turn on the clusterwarning with 108C.

3- Until 115C the system is degraded with FLIM curve, that reaches its maximum at 60% ofpower reduction.

Coolant temperature sensorEngine protection strategy NFB

1

2

3


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If the vehicle reaches 40Km/h, and there is no clutch signal change:


no power reduction

Clutch switchEngine protection strategy NFB


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Defect recognition if after run was interrupted orskipped

No lamp turns on (Does not work with actual L.U. SW)

no power reduction

error will be stored in Fault Memory

Defect recognition if PTO, VLSP ,VALC, FEOF, VMS5,CC and Hieghst engine speed values was corrupted


no power reduction

error will be stored in Fault Memory

E2PROMEngine protection strategy NFB


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Over3200 rpm(180cv) (cmol_n_warn):


error and the highest engine speed will be stored in Fault

Memory

Over 3800 rpm(cmol_n_max):

Stop lamp turns also on

quantity will be set to zero

error and the highest engine speed will be stored in Fault

Memory

* The highest reached engine speed can be read by the tester through the labelcmol_n_highest_w, that will be also saved at the freeze frames.

Engine OverspeedEngine protection strategy NFB


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Main RelayEngine protection strategy NFB





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If the message is not received for longer than the specified time or,

If any combination of CAN in bus off , Dual Port RAM (DPRAM)error , CAN stop is monitored for a longer than specified time thenno signal is recognised.

warning and wait to start lampturn on

no power reduction

CAN Controller Area NetworkEngine protection strategy NFB


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if crankshaft sensor is defective, the system is degraded at level 1.

if camshaft sensor is defective, the system is not degraded.

Crankshaft and camshaft signal missing

engine will be stopped, i.e. fuel pressure is set to zero, quantity is setto zero.

Engine Speed Camshaft and Crankshaft sensorsEngine protection strategy NFB


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If Pressure Relief Valve is recognized as opened:



Maximal rail pressure is limited to 80 MPa

Monitoring of pressure relief valveEngine protection strategy NFB


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Sensor defect recognition (only open load)

coolant empty lamp turn on

After 0 s:


degradation level is set at level 1.

Value below threshold

coolant empty lamp turn on

After 0 s:

Stop and engine failure lamp turn on

Degradation level is set at level 3.

Coolant empty level sensorEngine protection strategy NFB


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Coolant level sensorEngine protection strategy NFB

Fault LU response EDC7 response Degradation level

Only 'low' sensor open 0

Both sensors open 3

Only 'empty' sensor

open 3

sc/oc on 'low' sensor,

'empty' closed - 0

sc/oc on 'low' sensor,'empty' open

3

sc/oc on 'empty' ,

'low' closed 1

sc/oc on 'empty',

'low' open 1

Low' a) oc/sc to GND or

b) sc to VBAT or

c) out of range

'Empty' a) oc/sc to GND or

b) sc to VBAT or

c) out of range

1


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no power reduction


if there is water in fuel:

warning, engine failure and water in fuel lamp turn on

Degradation level is set at level 1

Water in fuel sensorEngine protection strategy NFB


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Defect recognition


degradation level is set at level 2

if two or more injectors is defective, the system is degraged at level3

Solenoid valveEngine protection strategy NFB


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Engine exhaust breakEngine protection strategy NFB



after 0s no power reduction


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Start relayEngine protection strategy NFB

Electrical System OverviewRemote Start NFB - MWM and International Engines- FMEA 004/04

ECM 1. REMOTE START (O) (Push Button) "pressed is closed"

Parking Brake Switch

"pressed is closed" IN

OUTIN

IN 2. REMOTE START ( I )(Push Button) "pressed is closed"

IN

IN

Neutral Switch Neutral position is closed

OUT

Tachograph

*CAN = Vss(Tachograph) + Gear Neutral (LU) + Cab Lock (LU) => Individual Messages

Vss

RPMIN

Ignition Switch KL15 (ON/OFF)

Start

Relay

Neutral

Switch

Starter

(2 x Cab Lock) Switch cab locked is closedLU

IN

IN

CAN*

IN

IN

Ignition Switch KL15 ON/OFF

Ignition Switch KL50 ON/OFF

Kl.15

(Authorization

Relay)

30

Ignition Switch

Kl.50

Vbat

+

Kl. 15

Radio

OFF


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Start relayEngine protection strategy NFB


It is not possible to recognize a relay failure with the actual Softwareand electrical diagram.

The neutral gang position on CAN, should be a precondition toenable the strart relay diagnosis.


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CP3 valve monitoringEngine protection strategy NFB





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If energising times of a cylinder exceed the limit,

overrun is detected

recovery is triggered


degradation level is set at level 3.

Overrun monitoringEngine protection strategy NFB


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If:

Tachograph or; service brake switch or; battery voltage,aredefective, only warning and engine failure lamp turn on and there isno system degradation level.

* EDC7 will not recognise if L.U., or Dashboard, or Warning or Stop

lamps are defective or desconnected.

Failures without power reductionEngine protection strategy NFB

Date post:	14-Feb-2018
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Engine Protection VW V3x Prop 02

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