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.

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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