PE09-024 HONDA 7/24/2009 ATTACHMENT Q8 QIS DOC 1 …pe09-024 honda 7/24/2009 attachment q8 qis doc 1 page 2, doc 2 pg 4, doc 3 pg 7, doc 4 pg 10 and q8 doc 5 pg 21

PE09-024 HONDA 7/24/2009

ATTACHMENT Q8 QIS

DOC 1 PAGE 2, DOC 2 PG 4, DOC 3 PG 7, DOC 4 PG 10 AND Q8 DOC 5 PG 21

PE09-024 HONDA 7/24/2009

ATTACHMENT Q8 DOC 1 ODYSSEY

QIS

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ATTACHMENT Q8 DOC 2 ACCORD

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PE09-024 HONDA 7/24/2009

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PE09-024 HONDA 7/24/2009


QIS












nancy ioki stone

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QIS No.:

Quality Engineering Report2006/2007YM ACCORD IMA

VSA failure DTC121-21

[Members]

Prepared on: 25th May, 2007


Occurrence Situation and Proposal 2/10-Contention, symptom: VSA warning lamp comes ON (*121-21: Regulator valve diagnosis)

“VSA, ABS, brake, ACT” comes ON-Particularities

-A lot of recurrences: 5 cases (Recurrence accounts for approx. 10%.) *It occurred four times resulting in buy-back.

-From HDS data vehicle info, warning light comes on when vehicle is at a stop.


Result of Recreation 3/10

■Result of recreation on market return failed carAlthough warning lamp coming ON was not recreated, we confirmed abnormal counting of failures in conjunction with CAS control ON/OFF at the time of brake release. ■Test date: 10th May, 2007, ■Test location: HRA-LA

■Test car: JHMCN36466C002514 (failed car)

Detected mismatch with L/R regulator monitor signal OFF right after regulator valve shifting to OFF at CAS control completion.


Estimating Factors 4/10

■FT analysis DTC121-21 detection

Monitor signal OFF is detected when REG valve is ON.

Software factor

Valve output is falsely

recognized as ON

Valve monitor is falsely

recognized as OFF

Abnormality in detection circuit

GND electric potential increase

solenoid electric

potential rise 5V Power

source drop

Abnormality of microcomputer

port

Abnormal resistance in partial pressure

circuit

Abnormality of detection circuit gate

Unexpected noise

No notable noise from on-car measurement results

Excluded because it recurs even though modulator is replaced.

Defect is found from software review and HILS check result.


Occurrence Mechanism 5/10

■Noncontrolled normal diagnosis operation Request for diagnosis valve

output?No

Yes All valves are OFF

All valves are OFF

Valve output buffer (previous value)

Valve output <- Diagnosis signal

Valve output buffer <- Diagnosis signal

Obtain valve monitor


Request for diagnosis valve output?

No

YesValve output buffer = valve monitor

Valve output buffer <- Valve output of this time

Clear request for valve output for diagnosis

Logic mismatch does not occur because it obtains monitor signal which is synchronized with output valve signal.

1ms processing

Goes through a path that outputs a test signal for diagnosis once per 20ms by a request from 20ms processing.

What’s obtained here is the valve condition which is outputting until just before.

Output processing of test signal for diagnosis

Output processing of signal for control

Comparison processing between test output and monitor signal


■Diagnosis operation at the time of control completion

Occurrence Mechanism 6/10


No

YesAll valves are OFF

All valves are OFF

Valve output buffer(previous value)






No

YesValve output buffer = valve monitor

Valve signal mismatch flag set

Valve output buffer<- Valve output of this time


1ms processing

Regulator valve monitor circuit

microcom

puter

Custom

IC

REG valve output REG valve

Monitor signal

REG valve output

Valve buffer logic

comparison

Valve monitor signal

Valve output for control that was held at the end of the last 1ms processing,

is referred to here.

PWM carrier cycle (1ms)

Mismatch here.

At the end of control, all valves have been confirmed to be OFF from last

output so that valve output for control and diagnosis will not continue.

Output processing of test signal for diagnosis

Output processing of signal for control

Comparison processing between test output and monitor signal

Updates latest valve monitor value

No output in the control completed loop, and valve output buffer remains at the previous value.

Compare the previous control signal and valve monitor signal right before completion of control.

At the end of PWM control, valve output is ON and valve monitor is OFF; logic mismatch


Occurrence Prediction 7/10

■Number of occurrence prediction

From current warranty occurrences (13 cases), number of occurrences were predicted using Weibull analysis.

284 units in 10 years (remaining 271 units)

Days # of defectsYear


Summary of Countermeasure 8/10

Comparison is carried out only at diagnosis valve output, so logic agrees without fail.

■Countermeasure spec■Countermeasure effect confirmation


No

Yes All valves are OFF

All valves are OFF

Valve output buffer (Last value)





Output notice flag?

Valve output buffer = valve monitor

Valve signal mismatch flag set

Valve output buffer <- Valve output of this time


1ms processing

Clear output notification flag

Set output notification flag

Run comparison processing based on output notification flag of the test signal.

Effect confirmation # of logic mismatches Max. fail count

135 CAS before countermeasure

135 CAS after countermeasure

Recreated repeated CAS operations in HILS.No mismatch between valve output and valve monitor.


Summary of Countermeasure 9/10

■Countermeasure content VSA software change

■Affected range 2006 / 2007YM ACCORD IMA

■Market action

■Countermeasure schedule


Recurrence Prevention 10/10

■Why-why analysis

■Recurrence preventive measures


11/10

END


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Documents

PE09-024 HONDA 7/24/2009 ATTACHMENT Q8 QIS DOC 1 …pe09-024 honda 7/24/2009 attachment q8 qis doc 1 page 2, doc 2 pg 4, doc 3 pg 7, doc 4 pg 10 and q8 doc 5 pg 21