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Product Training Airbag Volkswagen Group Airbag System / Airbag Control Units
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Product Training Airbag Volkswagen GroupAirbag System / Airbag Control Units+Satellites
Product Training Airbag VW
Page 1
SV C RS Q1 - M. Brger 07/04
Product Training Airbag Volkswagen GroupWhat means Safety Electronics?Airbag control units decide in case of a crash event,whether the belt pretensioner and airbag moduls will be fired or not. Airbag control units check steadily the whole airbag system in a car.Airbags should save life, not injure life!Complete protection by front, side, head airbags and belt pretensioner.Product Training Airbag VW
Page 2
SV C RS Q1 - M. Brger 07/04
Product Training Airbag Volkswagen GroupFront airbag deployment (pictures from high speed camera!)
10 ms after deployment15 ms30 ms1 ms = 1 milli second!
Product Training Airbag VW
Page 3
SV C RS Q1 - M. Brger 07/04
Product Training Airbag Volkswagen GroupSafety systems have active and passive componentsActive: Airbag system,ABS, ESP ...Passive: Constructive protection of the car body and a secure passenger cellProduct Training Airbag VW
Page 4
SV C RS Q1 - M. Brger 07/04
Product Training Airbag Volkswagen GroupAirbag systems contain electronic control units, satellites, airbag moduls and belt pretensioner
Driver module in the steering wheel,passenger module in the dash boardProduct Training Airbag VW
Page 5
SV C RS Q1 - M. Brger 07/04
Product Training Airbag Volkswagen Group
Cross section from a complete driver airbag module with a folded airbagCross section from aairbag module with firing squip and gas inflatorcollector ringProduct Training Airbag VW
Page 6
SV C RS Q1 - M. Brger 07/04
Product Training Airbag Volkswagen GroupDriver front airbag
inflatorsseveral squipsPassenger front airbag
inflatorsProduct Training Airbag VW
Page 7
SV C RS Q1 - M. Brger 07/04
Product Training Airbag Volkswagen GroupData transfer byCAN network
end of lineprogramming
AWLcrash outputHW-controlenginemanagement
diagnosisinterface
combi-instrumentCAN signal high, lowESP (VW8R)
telematic(navigation)
comfort control unit
airbag control unit VW61Check of periphery by"Stellgliedtest" with
VAG/VHS-Tester possiblProduct Training Airbag VW
Page 8
SV C RS Q1 - M. Brger 07/04
Product Training Airbag Volkswagen Groupexternal sensorscentral control unitparameter settinghardwarepower supply, firing circuitscontroller
crash parameter, car application, configuration stored in EEPROMfront, side satellitespassenger detection
airbag control unit with
SRE, SFA algorithm
MFT end of line file out ofFreigabetabelleAirbag System supplied by Siemens VDOProduct Training Airbag VW
Page 9
SV C RS Q1 - M. Brger 07/04
Product Training Airbag Volkswagen GroupAcceleration side satellitesg-Sat3 frontAcceleration side satellitesg-Sat3 rear
Airbag control unit VW61 (central unit)for side and head airbagsAirbag System supplied by Siemens VDOProduct Training Airbag VW
Page 11
SV C RS Q1 - M. Brger 07/04
Product Training Airbag Volkswagen GroupAcceleration satellitesg-Sat4Front satellitesECS4Airbag control unit VW8R (central unit)for side and head airbagsPressure satellites p -Sat4
Front crash sensors = earlycrash only for NAR marketAirbag System supplied by Siemens VDOProduct Training Airbag VW
Page 12
SV C RS Q1 - M. Brger 07/04
Assembly of the airbag control units and satellites in the vehic le, example VW Golfg-satellite
Control unit
g-satellite
Screwed on the middle tunnel
control unitProduct Training Airbag VW
Page 13
SV C RS Q1 - M. Brger 07/04
Assembly of the airbag control units and satellites in the vehic le, example VW PassatSatellites
Belt pretensionerSteering wheel with front airbag moduleSide/ Headairbags front and rearSide/ Headairbags
Collector ringControl unitPassenger airbag modSatellites
Belt pretensionerProduct Training Airbag VW
Page 14
SV C RS Q1 - M. Brger 07/04
Product Training Airbag Volkswagen Group
Airbag control unit VW61 (central unit)Acceleration satellitesg-Sat3 frontAcceleration satellitesg-Sat3 rearDiagnosis interfaceCAN-busWarning lampsAirbag SystemCrash output
Airbag modBelt pretensionBuckle switchesKey switchBattery deployment unitWiring harness + connectionsCollector ringProduct Training Airbag VW
Page 15
SV C RS Q1 - M. Brger 07/04
Product Training Airbag Volkswagen GroupFunctions of an Electronic control unit (ECU) VW3, VW51/52, VW61/62- Crash identification- Identification in x- (front) and y - (side) direction with integrated xy-g-sensor- Micro mechanic capacitive g-sensor (differential moveable capacitor)- Additional side crash identification with external side satellites (g -satellites)- Crash memory- Mechanical saving switch- External and internal failure detection of the complete airbag system- EEPROM fault memory- Diagnosis function / communication via CAN-Bus or K-Line- End of line programming function (vehicle specific crash parameters)Product Training Airbag VW
Page 19
SV C RS Q1 - M. Brger 07/04
Product Training Airbag Volkswagen GroupCrash Sensing in control units and satellites: Micromechanical acceleration sensingSMD Component1.3MicronGap2 MicronsThickSiignallProduct Training Airbag VW
Page 25
SV C RS Q1 - M. Brger 07/04
Product Training Airbag Volkswagen Groupleadframe
gel coverage
Micromechanicalacceleration sensing with Motorola SX 3209 for VW3, VW51, 61, 62g-cell with silicon gel coverage + amplifier asic on not separated metal leadframeNominal output voltage: 2,5V Spec. limit in ECU: 2,1 - 2,9V
g-cell foracceleration sensing
Filter/amplifier asic creates the electrical output signalProduct Training Airbag VW
Page 26
SV C RS Q1 - M. Brger 07/04
Product Training Airbag Volkswagen GroupMicromechanical acceleration sensing with AnalogDevices ADXL78/278 for VW8,81, 8R, AUDI8Rg-cell with 2 moveablestructures(differential capacitor)Single-Chip incl.g-cell + asicProduct Training Airbag VW
Page 27
SV C RS Q1 - M. Brger 07/04
Product Training Airbag Volkswagen Groupdifferentialcapacitormoveable massSpeed change= exterme braking, crash= negative acceleration
Movement of thesensing element due to inertia(moveable mass)= moveable electrical capacitor
Change of capacityat capacitor causes a change of the voltage ouput at the capacitor= change of the electrical signal
Change of signal atasic input causes an a change of the amplified signal output= informationfor the controllerNote: Everyone can experience this inertia effect in the car while br aking, the humanbody and other things are following the direction of the front movement => the bodywill be moved forward => the differential moveable capacitor will do the same!Product Training Airbag VW
Page 28
SV C RS Q1 - M. Brger 07/04
Airbag control units VW61/62, electrical main components / funct ionsfront airbag driver
front airbag pass.
side airbag driver front
side airbag pass. front
sideairbag driver rear
sideairbag pass. rear
head airbag driver
head airbag passengerUbattGND K-lineAWL
invers
Combined ASIC V1 - 3
safing sensor
4-Loop
SPI ASIC
belt pretensioner driver frontbelt pretensionerpass.- deact WLfront /side airbag
belt buckle switch driverbelt buckle switch pass.
Interface
Interface
Interface
MicrocontrollerMC68HC912D60(A)InterfaceInterfaceInterface
4-LoopSPI
ASIC
passenger frontbelt pretensioner driver rear *)belt pretensioner passenger rear *)pass. deact. switchfront / side airbag
CAN- Bus
crash- output
sidesatellite front right
sidesatellite front left
sidesatellite rear right
side satellite rear left
*) for version with12 firing loops,actually not in use @ VWProduct Training Airbag VW
Page 29
SV C RS Q1 - M. Brger 07/04
Airbag control units VW61/62, electrical main components / funct ionsControllerSatellite
Energy reserve,capacitorsInterfacesxy Acceleration sensorSatellite signals
Firing asicsFiring voltages
Mechanicalsafing sensorProduct Training Airbag VW
Page 30
SV C RS Q1 - M. Brger 07/04
Airbag control units VW61/62, electrical main components / funct ionsFiring asics (Infineon V1-3, 4Loop, 2Loop)-> integrated firing circuits with separate high and low side switches, voltage suppliesController (Motorola HC12)-> contains control unit program, crash algorithm, EEPROM failure memorySatellite interface asic (Temic U6268B)-> transforms current signal from satellites into a voltage signal for controller inputSafing sensor (Hamlin 041)-> mechanical reed switch -> contacts will close in case of crash situation for front airbagsAcceleration sensor (Motorola SX 3209)-> transforms mechanical movement (negative acceleration) into in electrical signalElectrolytic capacitors-> contain firing energy, voltage supply in case of interruption of battery connectionsProduct Training Airbag VW
Page 31
SV C RS Q1 - M. Brger 07/04
Assembled panel VW61Example5Wk 431311C0 909 605 F10 Firing Loops =2 Front airbags4 Side airbags2 Head airbags2 Belt pretensionerProduct Training Airbag VW
Page 32
SV C RS Q1 - M. Brger 07/04
Assembled panel VW51Example5Wk 431221C0 909 605 A6 Firing Loops =2 Front airbags2 Side airbags2 Belt pretensionerProduct Training Airbag VW
Page 33
SV C RS Q1 - M. Brger 07/04
gSat3 side satellites for sensing of the y-direction in vehicles
Side satellites are detecting the side accelerations of a vehicle; in every vehicle withside application are in minimum 2 satellites installed; the satellites have an owninternal crash algorithm, which creates an own firing decision. This firing signal will be transmitted to the control unit and be checked/compared with the result of the crash algorithm of the control unit. The unit will decide about the firing of the airbag moduls.Product Training Airbag VW
Page 35
SV C RS Q1 - M. Brger 07/04
gSat3 side satellites for sensing of the y-direction in vehicles6Q0 909 606gSat3 frontAssembly direction 90 to driving direction1C0 909 606gSat3 rearAssembly direction in driving directionProduct Training Airbag VW
satellite pre assembledsatellite moldedPage 36
SV C RS Q1 - M. Brger 07/04
gSat3 side satellites for sensing of the y-direction in vehiclesgSat3 layout assembly, componentsAcceleration sensor,Analog Devicesresonator
voltage regulator
mechanical codingsensing directionControllerPCB: frontrearProduct Training Airbag VW
Page 37
SV C RS Q1 - M. Brger 07/04
gSat4, ECS4 layout assembly, componentspoly-urethanepottingPCBSumitomoconnectorpress-fit pinsbushings forM6 screwProduct Training Airbag VW
marking molded into housing:VW-Logo, VW part number, measurement direction arrow, Siemens MLFB number,PBT GF30, Siemens VDOPage 38
SV C RS Q1 - M. Brger 07/04
gSat4, ECS4, sensor functionalityinput acceleration
existing g-cell (x,z)g-cellmemoryauxiliary circuits(power supply, clock generator)
data conditioning andstate machineinterface
ATIC56raw data to the ECU
ATIC56ATIC55
new ASIC
existing packageProduct Training Airbag VW
Page 39
SV C RS Q1 - M. Brger 07/04
pSat4, pressure sensor, layout assembly, componentsPressure based Side Impact Satellite SIS (p)General Characteristics unique electronic serial number water protection classIP53 supply voltage (max. rating)- 16...20 V supply voltage (op. range)6...12 V supply current5...8 mA signal current25...38 mA
poly-urethanepottingPCBSensing Characteristics temperature range-40+85C ambient pressure range600 to 1300 mbar measurement range-24 to +107 mbar/bar dynamic range0.3...360 Hz self test: comparison of two independent pressure cells on chipTime to fire of pressure based in comparison to acceleration bas ed sensing
molded TPEsealing ringsCrash SignalCar to Car 30km/h(JAP/AUS/EURO NCAP)806040
Pressure
press -fit pinsgSAT pSAT
SSiiggnnaall
200- 20- 40- 60
0 2 4 6 8 10 12 14 16 18 20 22 24 26
Accelerationsilicone sealfor pressure sensortFire Pressure
tFire Acceleration
Time in msSumitomoconnectorProduct Training Airbag VW
Page 40
SV C RS Q1 - M. Brger 07/04
Airbag control unit VW8/81, function flow during front crashCrash
125 mm ~ 50msDriverAirbag moduleAirbag
t = 0 st = 50 ms
30 msAirbag control unitCapacitor/Energy ReserveGas
T8xx
Safing TransistorsASIC with high/low side switchfiring squip
generatorConnector
V100
High side swV200Controllerlow side sw
xy -/ - xg- sensorsH300Product Training Airbag VW
Page 44
SV C RS Q1 - M. Brger 07/04
Airbag control unit VW61/62, function flow during front crashCrash
125 mm ~ 50msDriverAirbag moduleAirbag
t = 0 st = 50 ms
30 msAirbag control unitGas
H100
Hamlin
Capacitor/Energy ReserveASIC with high/low side switch=firing squip
generatorConnector
V100
High side swV200Controllerlow side sw
xy -g- SensorH300Product Training Airbag VW
Page 45
SV C RS Q1 - M. Brger 07/04
Airbag control unit VW61/62, function flow during front crashAirbag
Airbag control unitGas
H100
Hamlin
Capacitor/Energy ReserveASIC with high/low side switchfiring squip
generatorConnector
V100
High side swV200Controllerlow side sw
xy -g- SensorH3001) Micromechanic g-sensor recognizes a crash signal (mechanical movement);2) Controller checks the signal, takes the decision whether firing or not;3) Mechanical safing sensor (reed switch) closes due to the acceleration;4) Firing asic closes electronical high and low side switch by controller commando;5) Current flow from capacitor over safing sensor and asic to firing squip to ground;Product Training Airbag VW
Page 46
SV C RS Q1 - M. Brger 07/04
Airbag control unit VW61/62, function flow during side crashAirbag control unitfiring squip
Gas generator
Capacitor/Energy ReserveASIC with high/low side switch=High side swxy -g- SensorV200Connector
V100
Controllerlow side swV600V620Satellite interfaces
H300Product Training Airbag VW
Page 47
SV C RS Q1 - M. Brger 07/04
Airbag control unit VW61/62, function flow during side crash1) Satellite with micromechanic g-sensor recognizes acrash signal (mechanical movement)
firing squip2) Satellite controller checks the signal, takes the decision
Airbag control unitxy -g- SensorV200whether firing or not3) Satellite sends a fire signal to the airbag control unit4) Micromechanic y-g-sensor recognizes the same crash signal (mechanical movement= acceleration)
V100
ControllerV60 V620
H3005) Controller checks the signal, takes the decision whether firing or not;6) Controller checks the satellite decision, if satellite and controller confirm the crash7) Firing asic closes electronical high and low side switch by controller commando;8) Current flow starts from capacitor over asic to firing squip to ground;Product Training Airbag VW
Page 48
SV C RS Q1 - M. Brger 07/04
Airbag control unit VW61/62, how the electrical periphery in the car looks like?Satellite pass. rear
Side airbag passenger rear
Side airbag driver rear
Satellitedriver rearHead airbagpassenger side
Head airbag driver sideSatellitepass. front
Belt pretensioner passenger
Belt pretensioner driver
Satellitedriver rearSide airbagpassengerfront
Side airbagdriver frontKey switch for passengerfront airbag deactivationFront airbag passenger
Buckle Swit-ch passengerCAN Bus
Buckle Switch driverPassenger LED
Front airbag driverWarning lamp
2-LAooSpIC
X-Senso
r
g-celldata conditioning and
state machine
memory
interface
auxiliary circuits
(power supply, clock generator)
new ASIC
existing package
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