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  • Muhamad Farith Bin Pauzi

    14818

    Mechanical Engineering

    Industrial Internship Final Report (January 2014 August 2014)

    1

    STUDENT INDUSTRIAL PROJECT REPORT

    REVERSE-ENGINEERING OF AN ORIGINAL EQUIPMENT

    MANUFACTURER (OEM) DIAGNOSTIC TESTER

    ROBERT BOSCH SDN BHD

    NAME : MUHAMAD FARITH BIN PAUZI

    MATRIX ID : 14818

    PROGRAMME : MECHANICAL ENGINEERING

    DURATION : JANUARY 2014 AUGUST 2014

  • Muhamad Farith Bin Pauzi

    14818

    Mechanical Engineering

    Industrial Internship Final Report (January 2014 August 2014)

    3

    ACKNOWLEDGEMENT

    The author would like to express immense gratitude to Mr. Lee Ping Kooi, Head of Department of

    AA/SWA-TSS division for all the guidance, knowledge and useful advise that he has provided

    throughout the 28 weeks of internship period in Robert Bosch Sdn. Bhd. Mr. Lees professionalism,

    dedication and his spirit in Bosch is a great inspiration to the author.

    The author would also like to thank his supervisor, Mr. Mogana Das, SD Technical Service officer for

    providing the most of the technical knowledge and assistance throughout this internship. Mr. Moganas

    unconditional guidance has taught the author about the part and parcel of the software development

    process and its documentations. Furthermore his exceptional technical expertise in the automotive field is

    truly helpful in making the author understands the nature and subsequently completing all the tasks.

    Very special thanks to Mr. Charanjit, for providing unlimited support and information without hesitation

    in many tasks. Mr. Charanjits supportive advice during internship increases the morale of the team to

    work more on accomplishing task given. His expertise in automotive knowledge has been a very useful

    input for the author in understanding the industry much better.

    Besides that, the author would like to thank UTP supervisor, Dr Syed Ihtsham-ul-Haq Gilani. His advice

    and guidance is valuable in ensuring the successful completion of the internship program in accordance

    with guidelines drawn by UTP.

    Last but not least, the author would like to thank his parents and family and friends for their moral and

    financial support throughout the period of internship in Robert Bosch and also to express gratitude to

    those who helped the author directly and indirectly to complete the Internship Program.

  • Muhamad Farith Bin Pauzi

    14818

    Mechanical Engineering

    Industrial Internship Final Report (January 2014 August 2014)

    4

    TABLE OF CONTENTS

    VERIFICATION STATEMENT 2

    ACKNOWLEDGEMENT.............................................................. 3

    TABLE OF CONTENTS.. 4

    LIST OF FIGURES.. 6

    LIST OF TABLES. 7

    BRIEF INTRODUCTION TO ROBERT BOSCH. 8

    STUDENT INDUSTRIAL PROJECT REPORT

    1. Abstract and Introduction...........................................................................................18

    1.1. Objectives.. ........................................ 20

    1.2. Scope of Study ........................................................................................... 20

    1.3. Problem Statement.....................................................................21

    1.4. Relevancy of Project. ................................................................................. 22

    2. Background and Literature Review.......................................................................23

    3. Methadology .............................................................................................................. 27

    4. Results and Discussion .............................................................................................. 37

    5. Conclusion and Recommendation .............................................................................. 44

    6. Safety Training and Value of Practical Experience ................................................... 45

    6.1 Lesson Learnt and Experience Gained.......................................................48

  • Muhamad Farith Bin Pauzi

    14818

    Mechanical Engineering

    Industrial Internship Final Report (January 2014 August 2014)

    5

    6.2. Leadership, Team Work and Individual Activities...................................49

    6.3. Business Values, Ethics and Management Skills......................................50

    6.4. Problems / Challenges Faced and Solutions..............................................51

    7. References..................52

    8. Appendices ................................................................................................................ 53

  • Muhamad Farith Bin Pauzi

    14818

    Mechanical Engineering

    Industrial Internship Final Report (January 2014 August 2014)

    6

    LIST OF FIGURES

    Figure 1: Bosch Automotive Products 11

    Figure 2: Bosch Power Tools............................................................. 11

    Figure 3: Bosch Security Camera .................................................... 11

    Figure 4: Bosch Home Appliances ..11

    Figure 5: Robert Bosch Sdn Bhd ..... 13

    Figure 6: Directions to Robert Bosch Sdn .. 14

    Figure 7: AA Division Board of Management.................................... 15

    Figure 8: AA/SWA-TSS4 Organisation ............................................. 16

    Figure 9: KTS 570 .......................................................................... 19

    Figure 10: Bosch KTS Competitors............................................. 23

    Figure 11: System Difference of CAN and LIN ................ 26

    Figure 12: Reverse Engineering process Flow ....... 29

    Figure 13: Tools used for Internship Project...................................... 32

    Figure 14: 16-pin OBD Socket........................................................... 33

    Figure 15: Location Of The 16-pin OBD Diagnostic Socket.. 33

    Figure 16: Schematic diagram of traces taking................................... 34

    Figure 17: Connection to local cars with 16 pin OBD-socket............. 35

  • Muhamad Farith Bin Pauzi

    14818

    Mechanical Engineering

    Industrial Internship Final Report (January 2014 August 2014)

    7

    Figure 18: Schematic diagram of simulation....................................... 36

    Figure 19: Simulation connection........................................................ 37

    Figure 20: Step 1 Traces Taking....................................................... 38

    Figure 21: Example of Traces (CAN-Line)......................................... 39

    Figure 22: Step 2 Simulation............................................................ 40

    Figure 23: BDX Info............................................................................ 41

    Figure 24: BDX Specification............................................................. 42

    Figure 25: Bosch Values...................................................................... 43

  • Muhamad Farith Bin Pauzi

    14818

    Mechanical Engineering

    Industrial Internship Final Report (January 2014 August 2014)

    8

    LIST OF TABLES

    Table 1: Milestones of Bosch Automotive Products............. 10

    Table 2: Types of Car and Diesel Services........................................... 13

    Table 3: Bosch Safety Regulations............................... 46

  • Muhamad Farith Bin Pauzi

    14818

    Mechanical Engineering

    Industrial Internship Final Report (January 2014 August 2014)

    9

    Brief Introduction to Robert Bosch

    Robert Bosch GmbH Core Business

    Robert Bosch GmbH, a German diversified technology-based corporation which produces large scale of

    automotive and industrial products, such as household appliances, automotive component, power tools,

    CCTV and security system. Bosch also explores the anti-lock braking system (ABS) industry, Electronic

    Stability Programme (ESP) and has become a leader in specialized fields such as traction control systems

    (TCS). Besides that, BOSCH provides cutting-edged technology as well. The most renowned news

    among industries is the Green Technology project the use of renewable energy such as solar energy

    and wind energy, in which BOSCH is looking forward to the future.

    Types of Products

    Boschs core products are mainly automotive components including brakes, controls, electrical drives,

    electronics, fuel systems, generators, starter motors and steering systems. There are also industrial

    products such as drives and controls, packaging technology and consumer goods. Not to forget building

    products such as household appliances, power tools, security systems and thermo-technology.

    Below are the milestones of Bosch automotive products.

  • Muhamad Farith Bin Pauzi

    14818

    Mechanical Engineering

    Industrial Internship Final Report (January 2014 August 2014)

    10

    Year Product Description

    1887 Low-voltage magneto for stationary internal combustion engines

    1897 Installation of an ignition device in a motor vehicle

    1902 Spark plugs and high-voltage magneto ignition system

    1927 Fuel injection pumps for diesel engines

    1951 Gasoline injection pumps for internal combustion engines

    1957 Car transistor radios

    1967 Jetronic injection

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