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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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2 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
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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3 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
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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4 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
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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5 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
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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6 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
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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7 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
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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8 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
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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9 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
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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10 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
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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11 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
Boost air pressureEngine protection strategy NFB
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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12 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
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
Boost air pressureEngine protection strategy NFB
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13 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
Ambient Air PressureEngine protection strategy NFB
Sensor defect recognition
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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14 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
Sensor defect recognition
warning and engine failure lamp turn on
after 0 s no power reduction replacement value is-10 C
Value above threshold
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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15 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
Sensor defect recognition
warning and engine failure lamp turn on
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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16 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
Sensor defect recognition
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
Value above threshold
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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17 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
Acceleration pedalEngine protection strategy NFB
Sensor defect recognition
warning and engine failure lamp turn on
low idle speed is set to 1100 rpm(limp home mode)
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18 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
Sensor defect recognition
warning and engine failure lamp turn on
after 0 s degradation level 1
replacement value is 10 C to ensure coldstart
Coolant temperature sensorEngine protection strategy NFB
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19 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
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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20 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
Sensor defect recognition
If the vehicle reaches 40Km/h, and there is no clutch signal change:
warning and engine failure lamp turn on
no power reduction
Clutch switchEngine protection strategy NFB
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21 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
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
warning and engine failure lamp turn on
no power reduction
error will be stored in Fault Memory
E2PROMEngine protection strategy NFB
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22 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
Over3200 rpm(180cv) (cmol_n_warn):
warning and engine failure lamp turn on
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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23 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
Main RelayEngine protection strategy NFB
Sensor defect recognition
stop and engine failure lamp turn on
after 0 s the engine is degraded at level 3.
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24 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
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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25 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
Sensor defect recognition
warning and engine failure lamp turn on
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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26 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
If Pressure Relief Valve is recognized as opened:
stop and engine failure lamp turn on
after 0 s the engine is degraded at level 3.
Maximal rail pressure is limited to 80 MPa
Monitoring of pressure relief valveEngine protection strategy NFB
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27 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
Sensor defect recognition (only open load)
coolant empty lamp turn on
After 0 s:
warning and engine failure lamp turn on
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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28 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
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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29 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
Sensor defect recognition
warning and engine failure lamp turn on
no power reduction
Value above threshold
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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30 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
Defect recognition
stop and engine failure lamp turn on
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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31 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
Engine exhaust breakEngine protection strategy NFB
Sensor defect recognition
warning and engine failure lamp turn on
after 0s no power reduction
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32 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
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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33 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
Start relayEngine protection strategy NFB
Sensor defect recognition
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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34 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
CP3 valve monitoringEngine protection strategy NFB
Sensor defect recognition
stop and engine failure lamp turn on
after 0 s the engine is degraded at level 3.
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35 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
If energising times of a cylinder exceed the limit,
overrun is detected
recovery is triggered
stop and engine failure lamp turn on
degradation level is set at level 3.
Overrun monitoringEngine protection strategy NFB
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36 IAV GmbH 11/2005 tle ME-D5 HISP2.ppt
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